Rod DAEWOO LACETTI 2004 Service Repair Manual

FRONT SUSPENSION 2C – 11
DAEWOO V–121 BL4
4. Remove the brake caliper from the rotor. Support
the caliper so it does not hang from the hydraulic
brake hose. Refer to Section 4D, Front Disc
Brakes.
5. Remove the outer tie rod from the knuckle assem-
bly. Refer to Section 6C, Power Steering Gear.
6. On vehicles equipped with the antilock braking sys-
tem (ABS), disconnect the ABS speed sensor elec-
trical connection from the knuckle.
7. Remove the ball joint pinch bolt and the nut.
8. Separate the knuckle from the ball joint using the
ball joint remover KM–507–B.
9. Remove the nuts from the bolts that connect the
knuckle assembly to the strut assembly.

FRONT SUSPENSION 2C – 13
DAEWOO V–121 BL4
7. Connect the outer tie rod to the knuckle assembly.
Refer to Section 6C, Power Steering Gear.
8. Install the brake caliper onto the rotor. Refer to
Section 4D, Front Disc Brakes.
9. Install the caulking nut onto the axle shaft.
Tighten
Tighten the drive axle–to–hub caulking nut to 150
NSm (111 lb–ft). Loosen the nut, then retighten it to
275 NSm (126 lb–ft).
10. Install the wheel. Refer to Section 2E, Tires and
Wheels.
11. Lower the vehicle.
HUB AND BEARING
Tools Required
500–20 Hex Nut
J–36661–2 Forcing Screw
J–37105–B–1 Support Bridge
J–37105–B–2 Bearing Adapter
J–377105–B–3 Hub Adapter
Removal Procedure
1. Remove the drive axle from the front wheel hub.
Refer to ”Knuckle Assembly” in this section.
2. Remove the inner snap ring.
3. Remove the wheel hub with the support bridge
J–37105–B–1, the hub adapter J–377105–B–3, the
hex nut 500–20, and the forcing screw J–36661–2.
4. Remove the brake shield. Refer to Section 4D,
Front Disc Brakes.
5. Remove the outer snap ring.

2C – 18IFRONT SUSPENSION
DAEWOO V–121 BL4
3. Connect the stabilizer shaft link to the strut assem-
bly by attaching the stabilizer link–to–strut assem-
bly nut.
Tighten
Tighten the stabilizer link–to–strut assembly nut to 47
NSm (35 lb–ft).
4. Install the brake line to the securing bracket on the
strut assembly.
5. On vehicles equipped with the ABS, connect the
ABS sensor line to the strut assembly.
6. Install the wheel. Refer to Section 2E, Tires and
Wheels.
7. Lower the vehicle.
8. Install the nuts securing the strut assembly to the
body of the vehicle.
Tighten
Tighten the strut assembly–to–body nuts to 65 NSm
(48 lb–ft).
CROSSMEMBER ASSEMBLY
Removal Procedure
1. Raise and suitably support the vehicle.
2. Remove the wheels. Refer to Section 2E, Tires and
Wheels.
3. Remove the nuts and bolts from the steering gear
mounting bracket.
4. Remove the return line bolt from the clip on the
crossmember.
5. Remove the exhaust pipe forward of the catalytic
converter. Refer to Section 1G, Engine Exhaust.
6. Disconnect the tie rod from the knuckle assembly.
Refer to Section 6C, Power Steering Gear.
7. Disconnect the ball joint from the knuckle assembly.
Refer to ”Knuckle Assembly” in this section.
8. Disconnect the stabilizer link from the strut assem-
bly. Refer to ”Stabilizer Link” in this section.
9. Remove the crossmember link–to–transaxle brack-
et nut.
1) Remove the right lower engine mount.
2) Remove the rear transmission mount bracket.

2C – 20IFRONT SUSPENSION
DAEWOO V–121 BL4
6. Install the crossmember link–to–transaxle bracket
nut.
Tighten
Tighten the crossmember link–to–transaxle bracket
nut to 169 NSm (125 lb–ft).
7. Connect the stabilizer link to the strut assembly.
Refer to ”Stabilizer Link” in this section.
8. Connect the ball joint to the knuckle assembly. Re-
fer to ”Knuckle Assembly” in this section.
9. Connect the tie rod from the knuckle assembly. Re-
fer to Section 6C, Power Steering Gear.
10. Install the exhaust pipe into the vehicle. Refer to
Section 1G, Engine Exhaust.
11. Install the wheels. Refer to Section 2E, Tires and
Wheels.
12. Lower the vehicle.

2C – 22IFRONT SUSPENSION
DAEWOO V–121 BL4
Assembly Procedure
1. Press the control arm rear damping bushing into
the control arm using a press and the remover/in-
staller KM–158.
2. Install the split sleeves into the rear control arm
bushing.
3. Install the control arm. Refer to ”Control Arm” in
this section.
FRONT STRUT ASSEMBLY
Tools Required
KM–329–A Spring Compressor
J–42468 Front Strut Mount Nut Wrench
Disassembly Procedure
1. Remove the strut assembly. Refer to ”Strut Assem-
bly” in this section.
2. Fasten the strut assembly to the spring compressor
(DW320–010 or KM–329–A). Make sure the hooks
are seated on the strut spring properly.
3. Compress the front spring with the spring compres-
sor.
4. Use an open end wrench to hold the threaded pis-
ton rod while removing the piston rod nut and the
washer with a commercially available double ring
spanner, sharply offset.

FRONT SUSPENSION 2C – 23
DAEWOO V–121 BL4
Important : Record the position of the front spring locator
relative to the strut assembly–to–knuckle bracket. Place
the front spring locator back in the same position during
assembly.
5. Remove the upper strut mount, the mount bearing,
the upper spring seat, the upper ring insulator, and
the hollow bumper.
6. Release the spring.
7. Remove the spring and the lower ring insulator.
Assembly Procedure
1. Install the lower ring insulator and the spring.
2. Compress the spring using the spring compressor
KM–329–A.
3. Install the hollow bumper, the upper ring insulator,
the front spring locator, the upper spring seat, the
upper strut mount, and the mount bearing. Be sure
the upper spring seat is clipped to the front spring
locator.
4. Install the piston rod nut.
Tighten
Tighten the piston rod nut to 75 NSm (55 lb–ft).
5. Release the spring compresser KM–329–A
KNUCKLE
Disassembly Procedure
1. Remove the knuckle assembly from the vehicle.
Refer to ”Knuckle Assembly” in this section.
2. Remove the rotor. Refer to Section 4D, Front Disc
Brakes.
3. Remove the hub and bearing assembly. Refer to
”Hub and Bearing” in this section.
4. Remove the brake splash shield. Refer to Section
4D, Front Disc Brakes.

REAR SUSPENSION 2D – 17
DAEWOO V–121 BL4
UNIT REPAIR
SPRINGS AND INSULATORS
Tools Required
KM–329–A Spring Compressor
Disassembly Procedure
1. Remove the rear strut assembly from the vehicle.
Refer to ”Strut Assembly” in this section.
2. Mount the rear strut assembly into the spring com-
pressor (KM–329–A or DW320–010). Ensure that
the hooks are properly seated.
3. Compress the spring.
4. Remove the lock nut from the strut dampener rod.
5. Remove the rear strut mount.
6. Remove the rear spring upper seat, the dust cover,
and the hollow bumper.
7. Release the spring.
8. Remove the rear spring and the rear spring lower
seat.
Assembly Procedure
1. Install the rear spring lower seat and the rear
spring.
2. Compress the spring.
3. Install the hollow bumper, the dust cover, and the
rear spring upper seat.
4. Install the rear strut mount.

2D – 18IREAR SUSPENSION
DAEWOO V–121 BL4
5. Install the lock nut onto the strut dampener rod.
Tighten
Tighten the ball joint–to–control arm nuts to 100 NSm
(74 lb–ft). Tighten the strut dampener–to–strut mount
nut to 75 NSm (55 lb–ft).
6. Release the spring.
7. Remove the strut assembly from the spring com-
pressor and install the strut assembly into the ve-
hicle. Refer to ”Strut Assembly” in this section.
KNUCKLE
Disassembly Procedure
1. Remove the knuckle from the vehicle. Refer to
”Knuckle Assembly” in this section.
2. Remove the brake drum. Refer to Section 4E2,
Rear Drum Brakes.
3. Remove the wheel hub. Refer to ”Hub and Bearing
Assembly” in this section.
4. On vehicles equipped with rear drum brakes, re-
move the rear drum brake assembly. On vehicles
equipped with rear disc brakes, remove the rear
disc brake assembly. Refer to Section 4E1, Rear
Disc Brakes.
5. Remove the brake splash shield. Refer to Section
4E2, Rear Drum Brakes.
Assembly Procedure
1. Install the brake splash shield. Refer to Section
4E1, Rear Disc Brakes.
2. On vehicles equipped with rear drum brakes, install
the rear drum brake assembly. On vehicles
equipped with rear disc brakes, install the rear disc
brake assembly. Refer to Section 4E1, Rear Disc
Brakes.
3. Install the wheel hub. Refer to ”Hub and Bearing
Assembly” in this section.
4. Install the brake caliper and brake rotor or the
brake drum. Refer to Section 4E1, Rear Disc
Brakes and 4E2, Rear Drum Brakes.
5. Install the knuckle into the vehicle. Refer to
”Knuckle Assembly” in this section.

SECTION : 3A
AUTOMATIC TRANSAXLE DRIVE AXLE
TABLE OF CONTENTS
SPECIFICATIONS3A–1 . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 3A–1. . . . . . . . . .
SPECIAL TOOLS3A–2 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools Table 3A–2. . . . . . . . . . . . . . . . . . . . . . . .
COMPONENT LOCATOR3A–2 . . . . . . . . . . . . . . . . . . . .
Front Drive Axle 3A–2. . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE AND REPAIR3A–4 . . . . . . . . . . . . . . . ON–VEHICLE SERVICE 3A–4. . . . . . . . . . . . . . . . . . . . .
Drive Axle Assembly 3A–4. . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR 3A–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outer Joint Seal 3A–7. . . . . . . . . . . . . . . . . . . . . . . . . .
Inner Tripot Seal 3A–8. . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION3A–10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Drive Axle 3A–10. . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb–FtLb–In
Axle Shaft Caulking Nut300221–
Lower Ball Joint Pinch Bolt and Nut6044–
Tie Rod Nut5541–
Wheel Nuts10074–

3A – 4IAUTOMATIC TRANSAXLE DRIVE AXLE
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
DRIVE AXLE ASSEMBLY
Tools Required
KM–507–B Ball Joint Separator
DW340–110 Axle Shaft Remover
Removal Procedure
1. Raise and suitably support the vehicle.
2. 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. Remove the lower ball joint pinch bolt and nut.
5. Separate the steering knuckle from the lower ball
joint using the ball joint separator KM–507–B.
6. 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 separa-
tor KM–507–B.