Cavalier, Sunfire 2001-2005

Removal & Installation

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Automatic Transaxle



  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:
    WARNING
    Do not pull the halfshaft by the CV-joint boot or on the joint itself.



    Negative battery cable
     
    Front wheel
     
    Hub nut and washer
     
    Lower ball joint
     
    Wheel Speed Sensor (WSS) electrical connector
     
    Stabilizer bar link
     
    Halfshaft, press it from wheel bearing/hub assembly
     
    Halfshaft from the transaxle
     



    Click image to see an enlarged view

    Fig. To prevent damaging the transaxle or halfshaft, use the tools as shown to remove the halfshafts

  4.  

To install:

  1. Install the halfshaft into the transaxle (or intermediate shaft, if equipped) by placing a brass drift pin into the groove on the joint housing and tapping until seated. Be careful not to damage the axle seal or dislodge the seal garter spring when installing the axle.
    NOTE
    Be sure the halfshaft is fully engaged in the transaxle. Verify that the halfshaft is seated by grasping the inner joint housing and pulling outward. Do not pull on the shaft or the boot, but on the inner joint housing only.

  2.  
  3. Install or connect the following:

    Halfshaft into the hub/bearing assembly
     
    Stabilizer link. Torque the bolts to 13 ft. lbs. (17 Nm).
     
    WSS electrical connector
     
    Lower ball joint to the steering knuckle. Torque the nut to 41-48 ft. lbs. (55-65 Nm).
     
    Washer and a new hub nut. Torque the nut to 144 ft. lbs. (200 Nm).
     
    Front wheel
     
    Negative battery cable
     

  4.  

 
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