Chevrolet Sonic Repair Manual: Front Wheel Drive Shaft Replacement
Special Tools
J-45859 Axle Remover
For regional equivalent tools, refer to Special Tools.
- Removal Procedure
-
- Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
- Remove the front suspension skid plate bolts (1) and the front suspension
skid plate (2).
- Remove the tire and wheel assembly. Refer to Tire and Wheel Removal
and Installation.
Caution:
Make sure that the wheel drive shaft nut is fully
un-staked to avoid damage to the wheel drive shaft threads during the
removal of the wheel drive shaft nut. Failure to follow these instructions
could result in wheel, nut, and/or stud damage.
- Insert a brass drift or punch (1) in the cooling fins of the front
brake rotor (2).
- Rotate the brake rotor until it comes in contact with the brake caliper
mount bracket (5).
- Using the proper size socket (3) and a breaker bar (4), loosen the wheel
drive shaft nut.
- Remove and discard the wheel drive shaft nut (1). Replace with NEW only.
Note:
Reverse the wheel lug nuts and washers so the flat part
of the wheel nut is facing the washers.
- Attach the J-45859 remover (1) to the wheel hub using the wheel
lug nuts (2).
- Using the J-45859 remover (1) , separate the wheel drive shaft
from the wheel bearing/hub.
- Remove the stabilizer shaft link from the front strut. Refer to Stabilizer
Shaft Link Replacement.
- Remove the outer tie rod end from the steering knuckle. Refer to Steering
Linkage Outer Tie Rod Replacement.
- Remove the lower control arm bolt from the steering knuckle. Refer to
Lower Control Arm Replacement.
- With the aide of an assistant, move the steering knuckle to the side.
- Using a long screw driver (2), remove the wheel drive shaft (1) from
the transmission.
- Remove the wheel drive shaft (1) from the vehicle.
Note:
If there is no washer on the wheel drive shaft, install
a NEW washer.
- Remove and discard the washer (1) from the wheel drive shaft (2). Do
not re-use the washer, replace with NEW only.
- Installation Procedure
-
- Position the wheel drive shaft (1) in the vehicle.
- Install the special tool (1) in the output shaft seal.
- Install the wheel drive shaft (2).
- Remove the special tool (1).
- Install the lower control arm ball joint bolt to the steering knuckle.
Refer to Lower Control Arm Replacement.
- Install the stabilizer shaft link to the front strut. Refer to Stabilizer
Shaft Link Replacement.
- Install the outer tie rod to the steering knuckle. Refer to Steering
Linkage Outer Tie Rod Replacement.
- Install the NEW wheel drive shaft nut (1).
- Insert a brass drift or punch (5) in the cooling fins of the front
brake rotor (4).
- Rotate the brake rotor until it comes in contact with the brake caliper
mount bracket (1).
Caution:
Refer to Fastener Caution.
Note:
- There are two types of the wheel drive shaft nuts, which have
different tightening torque specifications. Check the style nut
that is on the vehicle when staking the nut.
- Style 1 nut has the thin collar (1.5 mm) thickness.
- Style 2 nut has the thick collar (2.7 mm) thickness.
- Using the proper size socket and torque wrench, tighten the NEW wheel
drive shaft nut to:
- For Style 1, 330 Y (244 lb ft)
- For Style 2, First Pass: 50 Y (37 lb ft)
- For Style 2, Final Pass: plus 60 degrees.
- Using appropriate tools (3), stake the wheel drive shaft nut collar into
the slot on the wheel drive shaft.
- Style 1: Stake the center of the wheel drive shaft nut (1) and ensure
it is fully staked. DO NOT fractured the wheel drive shaft nut. Each side
of the stake should be in contact with the slot in the wheel drive shaft.
The gap between the bottom of the stake in the wheel drive shaft nut and
the bottom of the slot in the wheel drive shaft should be less than 1 mm
(0.039 in)
.
- Style 2: Evenly split the center of the wheel drive shaft nut (2) and
ensure that it is fully staked. Each side of the stake should be in contact
and approximately 45° to each side of the slot in the wheel drive shaft.
- Install the front suspension skid plate (2).
- Install the front suspension skid plate bolts (1) and tighten to 22 Y
(16 lb ft).
- Install the tire and wheel assembly. Refer to Tire and Wheel Removal and
Installation.
- Remove the support and lower the vehicle.
Special Tools
DT-35910 Drive Axle Boot Clamp Pliers
For equivalent regional tools, refer to Special Tools
Disassemble Procedure
Remove the wheel drive shaft from the vehicle. Refer ...
Front Wheel Drive Shaft Seal Replacement - Case Side
Callout
Component Name
1
Front Wheel Drive Shaft Oil Seal
Specia ...
Other materials:
Forward Collision Alert (FCA) System
For vehicles with this feature, read the following section before using it.
The Forward Collision Alert (FCA) system may help to avoid or reduce the harm
caused by front-end crashes. FCA provides a flashing red visual alert and beeps
when approaching a vehicle directly ahead too quickly. FCA al ...
If No Steam Is Coming from the Engine Compartment
If an engine overheat warning is displayed but no steam can be seen or heard,
the problem may not be too serious. Sometimes the engine can get a little too hot
when the vehicle:
Climbs a long hill on a hot day.
Stops after high-speed driving.
Idles for long periods in traffic.
If the ...
Strut and Shock Absorber Inspection (Shock Absorber)
Note: The shock absorber assembly DOES NOT have to be removed from
the vehicle to perform the following inspection procedure.
Note: A light film of oil on the top portion of the lower shock absorber
tube is normal. DO NOT replace the shock absorber for this condition.
Condition ...
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