Aveo 2006-2007

Halfshafts

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CV-Joints



Overhaul
Inner Joint
  1. Remove the large and small boot clamps and discard the clamps.
  2.  
  3. Separate the joint housing from the boot.
  4.  
  5. Remove the grease from the tripod.
  6.  
  7. Remove the axle shaft retaining ring.
  8.  
  9. Remove the tripod joint retaining ring.
  10.  
  11. Remove the tripod joint seal.
  12.  
  13. Install a new small seal clamp on the seal.
  14.  
  15. Install the seal onto the axle shaft.
  16.  
  17. Install the axle shaft retaining ring.
  18.  
  19. Fill the tripod joint with 6.9-7.6 ounces of grease on auto. trans. models, or 4.2-4.96 ounces of grease on manual transaxle models.
  20.  
  21. Install the new boot.
  22.  
  23. Install a new large and small clamp on the boot and crimp the clamps.
  24.  

Outer Joint
  1. Remove the large and small boot clamps and discard the clamps.
  2.  
  3. Remove the boot.
  4.  
  5. Remove the grease from the joint.
  6.  
  7. Compress the snap ring and remove the joint from the shaft.
  8.  
  9. Remove the seal from the axle shaft.
  10.  
  11. Install a new seal on the axle shaft
  12.  
  13. Install a new joint to the shaft.
  14.  
  15. Fill the joint seal with 3.9-4.6 ounces of grease.
  16.  
  17. Install the new boot.
  18.  
  19. Install a new large and small clamp on the boot and crimp the clamps.
  20.  

Removal & Installation



  1. Raise and safely support the vehicle.
  2.  
  3. Remove the front wheels.
  4.  
  5. Remove the engine undercovers.
  6.  
  7. Remove the axle shaft nut and discard.
  8.  
  9. Remove the lower ball joint nuts.
  10.  
  11. Separate the steering knuckle from the lower ball joint using Special Tool KM-507-C or suitable ball joint remover tool.
  12.  
  13. Remove the tie rod nut.
  14.  
  15. Separate the tie rod end using Special Tool KM-507-C or suitable ball joint remover tool.
  16.  
  17. Remove the damping block connection nut and bolt.
  18.  
  19. Remove the rear mounting bracket.
  20.  
  21. Push the axle shaft from the wheel hub.
  22.  
  23. Remove the axle shaft from the transaxle using Special Tool DT-47539 Axle Shaft remover.
    WARNING
    Place a drain pan below the transaxle to catch any transaxle fluid that may spill.


    NOTE
    Cap the transaxle opening after the axle shaft has been removed to avoid contamination.

  24.  

To install:

  1. Clean the hub seal and transaxle seal.
  2.  
  3. Install the axle shaft into the transaxle.
  4.  
  5. Install the wheel hub onto the axleshaft.
  6.  
  7. Install the rear mounting bracket. Tighten the mounting bolts to 44 ft. lbs. (60 Nm).
  8.  
  9. Install the damping block connection nut and bolt and tighten to 59 ft. lbs. (80 Nm).
  10.  
  11. Mount the steering knuckle onto the lower ball joint.
  12.  
  13. Install the tie rod into the knuckle/strut and tighten the tie rod nut to 33 ft. lbs. (45 Nm)
  14.  
  15. Install the lower ball joint nut and tighten to 37 ft. lbs. (50 Nm).
  16.  
  17. Loosely install a new axle nut.
    CAUTION
    Always use a new axle shaft nut when reinstalling.

  18.  
  19. Install the wheels, loosely install the lug nuts.
  20.  
  21. Lower the vehicle.
  22.  
  23. Tighten the lug nuts to 88 ft. lbs. (120 Nm).
  24.  
  25. Tighten the axle shaft nut to 221 ft. lbs. (300 Nm).
  26.  
  27. Peen the axle shaft nut with a punch and hammer until the nut is locked in place.
  28.  
  29. Install the engine undercovers.
  30.  
  31. Refill the transaxle with fluid to the correct level.
  32.  

 
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