Chevrolet Sonic Repair Manual: Front Wheel Drive Shaft Outer Joint and Boot Replacement
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 to Front Wheel
Drive Shaft Replacement.
- Install the drive axle shaft (1) in a soft jawed vice.
Caution:
Do not cut through the wheel drive shaft inboard
or outboard boot during service. Cutting through the boot may damage
the sealing surface of the housing and the tripot or the constant velocity
joint bushing. Damage to the sealing surface may lead to water and dirt
intrusion and premature wear of the constant velocity joint.
- Using a pair of side cutters, remove the outer boot clamp (1) and the
inner boot clamp (2).
- Discard the boot clamps (1) and (2). Use NEW clamps only.
- Remove the CV joint (2) from the wheel drive shaft (1) while tapping
the inner race (3) using a bronze bar and a hammer.
- Using the appropriate tool, remove and discard the retaining clip.
- Remove the boot (1) from the wheel drive shaft (2).
- Inspect the outer CV joint for damage and wear. Refer to Wheel Drive
Shaft Outer Joint Inspection.
- Assemble Procedure
-
- Position the boot (1) on the wheel drive shaft (2).
- Using the appropriate tool, install the NEW retaining clip.
- Ensure that the boot (1) is properly seated in the grooved (2) wheel
drive shaft (3).
- Place approximately half the lubricant from the service kit inside the
outboard boot and pack the CV joint with the remaining lubricant.
- Using a block of wood and a hammer, install the CV joint (1) on the
wheel drive shaft.
- Install the inner boot clamp (2) and the outer boot clamp (1).
Note:
Ensure that the boot clamp is properly positioned around
the entire circumference of the boot.
- Using the DT-35910 pliers and a torque or ratchet wrench and
breaker bar (1), close the boot clamp (2) until the gap (3) measures
1.9 mm (0.07 in)
.
- Using the DT-35910 pliers and a torque or ratchet wrench (2) and
breaker bar (3), close the boot clamp (1) until the gap (4) measures
1.7 mm (0.06 in)
.
- Distribute the lubricant within the outer CV joint by moving it in a
circular motion at least four to five times.
- Remove the wheel drive shaft from the bench vise.
- Install the wheel drive shaft assembly. Refer to Front Wheel Drive Shaft
Replacement.
Special Tools
DT-35910 Drive Axle Boot Clamp Pliers
For equivalent regional tools, refer to Special Tools.
Disassemble Procedure
Note: There are types of inner joints available. If ...
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.
...
Other materials:
Front Seats
The front seats have adjustable head restraints in the outboard seating positions.
Adjust the head restraint so that the top of the restraint is at the same height
as the top of the occupant's head. This position reduces the chances of a neck injury
in a crash.
The height of the head r ...
Rear Window Panel Trim Replacement
Rear Window Panel Trim Replacement
Callout
Component Name
Preliminary Procedures
Remove the body lock pillar upper trim panel. Refer to Body Lock
Pillar Upper Trim Panel Replacement.
Remove the body rear seat back trim pa ...
Rear Disc Brake Pads Replacement
Removal Procedure
Warning: Refer to Brake Dust Warning.
Note: Always replace disc brake pads in axle sets.
Inspect the fluid level in the brake master cylinder reservoir.
If the brake fluid level is midway between the maximum-full point and
the minimum allowab ...
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