Text preview for : en_4j2_3b.pdf part of Daewoo Nubira/Lacetti Also known as: Chevrolet Nubira / Lacetti, Chevrolet Optra Optra5, Suzuki Forenza Reno Covers the 1.4L, 1.6L and 1.8L engine. Year 2004



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SECTION : 3B

MANUAL TRANSAXLE DRIVE AXLE
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 3B1 Fastener Tightening Specifications . . . . . . . . . . 3B1 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B2 Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . . 3B2 COMPONENT LOCATOR . . . . . . . . . . . . . . . . . . . . 3B2 Front Drive Axle . . . . . . . . . . . . . . . . . . . . . . . . . . 3B2 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 3B5 ONVEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 3B5 Drive Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . 3B5 UNIT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B8 Outer Joint Seal . . . . . . . . . . . . . . . . . . . . . . . . . . 3B8 Inner Tripot Seal . . . . . . . . . . . . . . . . . . . . . . . . . . 3B9 Cross Groove Joint Seal . . . . . . . . . . . . . . . . . . . 3B11 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B13 Front Drive Axle . . . . . . . . . . . . . . . . . . . . . . . . . 3B13

SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Application Axle Shaft Caulking Nut Lower Ball Joint Pinch Bolt and Nut Tie Rod Nut Wheel Nuts NSm 300 60 55 100 LbFt 221 44 41 74 LbIn

3B 2IMANUAL TRANSAXLE DRIVE AXLE

SPECIAL TOOLS
SPECIAL TOOLS TABLE

J8059 Snap Ring Pliers

KM460A Axle Shaft Remover

KM507B Ball Joint Remover

J35566 Seal Clamp Pliers

COMPONENT LOCATOR
FRONT DRIVE AXLE

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MANUAL TRANSAXLE DRIVE AXLE 3B 3

1. 2. 3. 4. 5. 6.

Caulking Nut C/V Joint Axle Shaft Seal Retaining Clamp Drive Axle Outboard Seal Seal Retaining Clamp

7. 8. 9. 10. 11. 12.

Seal Retaining Clamp Drive Axle Inboard Seal Seal Retaining Clamp Race Retaining Ring Cross Groove Joint Retaining Ring

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3B 4IMANUAL TRANSAXLE DRIVE AXLE

1. 2. 3. 4. 5. 6.

C/V Joint Assembly C/V Joint Seal Retaining Clamp Drive Axle Outboard Seal Seal Retaining Clamp Axle Shaft

7. 8. 9. 10. 11. 12.

Seal Retaining Clamp Drive Axle Inboard Seal Seal Retaining Clamp Tripot Housing Snap Ring Tripot Joint Assembly

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MANUAL TRANSAXLE DRIVE AXLE 3B 5

MAINTENANCE AND REPAIR
ONVEHICLE SERVICE DRIVE AXLE ASSEMBLY
Tools Required KM507B Ball Joint Separator KM460A Axle Shaft Remover

Removal Procedure
1. 2. Raise and suitably support the vehicle. Remove the wheels. Refer to Section 2E, Tires and Wheels.

3.

Remove the axle shaft caulking nut. Discard the nut.

Notice : Use only the recommended tool for separating the lower ball joint. Failure to use the recommended tool may cause damage to the ball joint and the seal. 4. 5. 6. Remove the lower ball joint pinch bolt and nut. Separate the steering knuckle from the lower ball joint using the ball joint separator KM507B. Remove the tie rod nut.

Notice : Use only the recommended tool for separating the tie rod from the knuckle/strut assembly. Failure to use the recommended tool may cause damage to the knuckle/ strut assembly. 7. Separate the tie rod end using the ball joint separator KM507B.

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3B 6IMANUAL TRANSAXLE DRIVE AXLE
8. Push the drive axle shaft from the wheel hub. Important : Support the unfastened end of the drive axle. Do not allow the drive axle to dangle freely from the transaxle for any length of time after it has been removed from the wheel hub. Important : Place a drain pan below the transaxle to catch the escaping fluid. Cap the transaxle drive opening after the drive axle has been removed to keep the fluid in and any contamination out. 9. Remove the drive axle from the transaxle using the axle shaft remover KM460A.

Installation Procedure
Notice : Do not damage the seals. 1. Clean the hub seal and the transaxle seal. 2. Install the drive axle into the transaxle. 3. Install the wheel hub onto the axle shaft.

4.

Install the tie rod into the knuckle/strut and install the tie rod nut.

Tighten
Tighten the tie rod nut to 55 NSm (41 lbft).

5.

Install the lower ball joint pinch bolt and nut.

Tighten
Tighten the lower ball joint pinch bolt and nut to 60 NSm (44 lbft).

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MANUAL TRANSAXLE DRIVE AXLE 3B 7
6. Loosely install a new axle shaft caulking nut. Always use a new nut.

7. 8.

Install the wheels. Loosely install the nuts. Refer to Section 2E, Tires and Wheels. Lower the vehicle to the floor.

Tighten
Tighten the wheel nuts to 100 NSm (74 lbft). 9. Tighten the axle shaft caulking nut to 300 NSm (221 lbft). 10. Peen the caulking nut with a punch and a hammer until the nut is locked into place on the axle shaft hub. 11. Refill the transaxle fluid to the proper level. Refer to Section 5B, FiveSpeed Manual Transaxle.

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3B 8IMANUAL TRANSAXLE DRIVE AXLE

UNIT REPAIR OUTER JOINT SEAL
Tools Required J8059 Snap Ring Pliers J35566 Seal Clamp Pliers

Removal Procedure
1. 2. 3. 4. 5. Remove the drive axle from the vehicle. Refer to "Drive Axle Assembly" in this section. Remove the large seal retaining clamp. Discard the clamp. Remove the small seal retaining clamp. Discard the clamp.

Degrease the joint. Spread the snap ring using the snap ring pliers J8059 and remove the outer joint the axle shaft. CAUTION : Do not remove the axle shaft from the outer joint assembly or disassemble the outer joint assembly. Parts are match fit and cannot be serviced separately.Improper reassembly will adversely affect both performance and safety. 6. Remove the seal from the joint assembly.

Installation Procedure
1. 2. 3. Install the seal onto the axle shaft. Spread the snap ring using the snap ring pliers J8059 and remove the outer joint the axle shaft. Fill the joint seal with 110 to 130 g (3.9 to 4.6 ounces) of the recommended grease. Repack the joint with 110 to 130 g (3.9 to 4.6 ounces) of the recommended grease. S 1.8 DOHC : 120 to 140g (4.2 to 4.9 ounces)

4. 5.

6.

Install a new large seal retaining clamp and a new small seal retaining clamp. Crimp the new small seal retaining clamp and the new large seal retaining clamp using the seal clamp pliers J35566. Install the drive axle shaft to the vehicle. Refer to "Drive Axle Assembly" in this section.

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MANUAL TRANSAXLE DRIVE AXLE 3B 9

INNER TRIPOT SEAL
Tools Required J35566 Snap Ring Pliers J8059 Snap Ring Pliers

Removal Procedure
1. 2. 3. Remove the drive axle from the vehicle. Refer to "Drive Axle" in this section. Remove the large seal retaining clamp. Discard the clamp. Remove the small seal retaining clamp. Discard the clamp. Separate the joint housing from the boot.

4.

5. 6.

Degrease the tripot assembly. Remove the shaft retaining ring using the snap ring pliers J8059.

7. 8.

Remove the tripot and the tripot joint retaining ring from the axle shaft. Remove the tripot joint seal from the axle shaft.

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3B 10IMANUAL TRANSAXLE DRIVE AXLE Installation Procedure
Tools Required J8059 Snap Ring Pliers J35566 Seal Clamp Pliers 1. Install a new small seal retaining clamp onto the seal. 2. Install the seal onto the axle shaft.

3.

Install the shaft retaining ring onto the axle shaft using the snap ring pliers J8059.

4.

5.

Fill the tripot housing with 195 to 215 g (6.9 to 7.6 ounces) of the recommended grease. Repack the tripot with 195 to 215 g (6.9 to 7.6 ounces) of the recommended grease. Install the boot to the joint housing.

6.

7. 8.

Install a new large seal retaining clamp. Crimp the large seal retaining clamp using the seal clamp pliers J35566. Crimp the new small seal retaining clamp using the seal clamp pliers J35566. Install the drive axle shaft to the vehicle. Refer to "Drive Axle Assembly" in this section.

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MANUAL TRANSAXLE DRIVE AXLE 3B 11

CROSS GROOVE JOINT SEAL
Tools Required J35566 Seal Clamp Pliers J8059 Snap Ring Pliers

Removal Procedure
1. 2. Remove the large seal retaing clamp.Discard the clamp. Remove the small seal retaining clamp. Discard the clamp. Degrease the joint. Remove the shaft retaining ring using the snap ring pilers J8059.

3. 4.

5. Remove the axle shaft from the joint assembly. CAUTION : The ball retainer is staked in position and must not be disassmbled. Cross groove joint internal parts are match fit and cannot be serviced separately. Improper reassembly will adversely affect both performance and safety. 6. Remove the seal from the joint assembly.

Installation Procedure
1. 2. 3. Install a new small seal retaining clamp onto the seal. Do not crimp. Install the seal onto the axle shaft. Install the joint assembly onto the axle shaft.

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3B 12IMANUAL TRANSAXLE DRIVE AXLE
4. Install the shaft retaining ring using the snap ring pilers J8059.

5.

6. 7. 8.

Fill the joint assembly with 120 to 140 g (4.2 to 4.9 ounces) of the recommended grease. Repack the tripot with 120 to 140 g (4.2 to 4.9 ounces) of the recommended grease. Install the a new large seal retaining clamp. Crimp the new large seal retaining clamp using the seal clamp pliers J35566. Crimp the new small retaining clamp using the seal clamp pliers J35566.

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GENERAL DESCRIPTION AND SYSTEM OPERATION
FRONT DRIVE AXLE
General Description
Drive axles are flexible shaft assemblies that transmit a rotational force from the transaxle to the frontwheel assemblies. Each axle assembly consists of an inner

constantvelocity joint and an outer constantvelocity joint connected to an axle shaft. The inner joint is completely flexible and has the ability to move in and out. The outer joint is also flexible, but it cannot move in and out. The drive axles use one type of outboard joint and two types of inboard joints.

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