Front Drive Axle Inner Shaft Replacement. Chevrolet Joy 2008

For 1990-2009 cars

### Removal Procedure

1. Press the brake pedal in order to disable the rotation of the hub.
2. Loosen the caulking (1).
3. Remove the drive axle shaft nut (3).
4. Discard the nut.
5. Remove the washer (2).
6. Remove the wheel and tire assembly
7. Remove the transaxle under cover bolts (2).
8. Remove the transaxle under cover (1).
9. Drain the transaxle fluid through the drain plug.
10. Remove the strut bar. Refer to Stabilizer Shaft Replacement.

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 of the tie rod end.

11. Separate the control arm ball joint (1) and the tie rod end from the knuckle (2). Refer to Steering Knuckle Replacement

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.

12. Pull the drive axle shaft (1) from the wheel hub.
13. Insert a flat-head screwdriver between the transaxle case and the drive axle joint case (2).

Notice: Refer to Drive Axle Notice in the Preface section.

14. Remove the drive axle (1) from the transaxle.

### Inspection Procedure

1. Inspect for worn or damaged spline of drive axle (1).
2. Inspect for a leaking boot (2).
3. Inspect for a bent shaft (3).

### Installation Procedure

1. Clean the transaxle seal.
2. Install the drive axle into the transaxle.
3. Install the wheel hub onto the drive axle shaft.
4. Mount the knuckle onto the control arm ball joint. Refer to Steering Knuckle Replacement

Notice: Refer to Fastener Notice in the Preface section.

5. Install the control arm ball joint bolt (1).

Tighten
Tighten the control arm ball joint bolt to 50-70 N·m (36-52 lb ft).

6. Install the tie rod into the knuckle and install the tie rod end joint castellated nut (2).

Tighten
Tighten the tie rod end joint castellated nut to 30-55 N·m (21-41 lb ft).

7. Install the strut bar, strut bar mounting bolts (1) and castellated nut (2).

Tighten

• | Tighten the strut bar mounting bolts 33-53 N·m (24-39 lb ft).

• | Tighten the strut bar castellated nut to 40-50 N·m (30-36 lb ft).

Important: Always use a new nut. Always peen the caulking nut with a punch and a hammer until the nut is locked into place on the wheel hub.

8. Install the drive axle shaft nut (2).

Tighten
Tighten the drive axle shaft nut to 210 N·m (155 lb ft).

9. Install the wheel and tire assembly.
10. Tighten the drain plug (3).

Tighten
Tighten the drain plug to 25-30 N·m (18-22 lb ft).

11. Remove the oil level plug (1).
12. Refill recommended fluid to the proper level.
13. Tighten the oil level plug (2).

Tighten
Tighten the oil level plug to 36-54 N·m (26-40 lb ft).

Classification
75W-85 (GL-4)

Capacity
2.1L (2.21 qt)

14. Install the transaxle under cover with the bolts (1).

Tighten
Tighten the transaxle under cover bolts to 35-55 N·m (25-41 lb ft).