tran DAEWOO LACETTI 2004 Service Repair Manual

MANUAL TRANSAXLE DRIVE AXLE 3B – 5
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
DRIVE AXLE ASSEMBLY
Tools Required
KM–507–B Ball Joint Separator
KM–460–A 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.

3B – 6IMANUAL TRANSAXLE DRIVE AXLE
DAEWOO V–121 BL4
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 trans-
axle 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 KM–460–A.
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 lb–ft).
5. Install the lower ball joint pinch bolt and nut.
Tighten
Tighten the lower ball joint pinch bolt and nut to 60
NSm (44 lb–ft).

MANUAL TRANSAXLE DRIVE AXLE 3B – 7
DAEWOO V–121 BL4
6. Loosely install a new axle shaft caulking nut. Al-
ways use a new nut.
7. Install the wheels. Loosely install the nuts. Refer to
Section 2E, Tires and Wheels.
8. Lower the vehicle to the floor.
Tighten
Tighten the wheel nuts to 100 NSm (74 lb–ft).
9. Tighten the axle shaft caulking nut to 300 NSm (221
lb–ft).
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, Five–Speed Manual Transaxle.

3B – 8IMANUAL TRANSAXLE DRIVE AXLE
DAEWOO V–121 BL4
UNIT REPAIR
OUTER JOINT SEAL
Tools Required
J–8059 Snap Ring Pliers
J–35566 Seal Clamp Pliers
Removal Procedure
1. Remove the drive axle from the vehicle. Refer to
”Drive Axle Assembly” in this section.
2. Remove the large seal retaining clamp. Discard the
clamp.
3. Remove the small seal retaining clamp. Discard the
clamp.
4. Degrease the joint.
5. Spread the snap ring using the snap ring pliers
J–8059 and remove the outer joint the axle shaft.
CAUTION : Do not remove the axle shaft from the out-
er joint assembly or disassemble the outer joint as-
sembly. Parts are match fit and cannot be serviced se-
parately.Improper reassembly will adversely affect
both performance and safety.
6. Remove the seal from the joint assembly.
Installation Procedure
1. Install the seal onto the axle shaft.
2. Spread the snap ring using the snap ring pliers
J–8059 and remove the outer joint the axle shaft.
3. 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. Install a new large seal retaining clamp and a new
small seal retaining clamp.
5. Crimp the new small seal retaining clamp and the
new large seal retaining clamp using the seal clamp
pliers J–35566.
6. Install the drive axle shaft to the vehicle. Refer to
”Drive Axle Assembly” in this section.

MANUAL TRANSAXLE DRIVE AXLE 3B – 9
DAEWOO V–121 BL4
INNER TRIPOT SEAL
Tools Required
J–35566 Snap Ring Pliers
J–8059 Snap Ring Pliers
Removal Procedure
1. Remove the drive axle from the vehicle. Refer to
”Drive Axle” in this section.
2. Remove the large seal retaining clamp. Discard the
clamp.
3. Remove the small seal retaining clamp. Discard the
clamp.
4. Separate the joint housing from the boot.
5. Degrease the tripot assembly.
6. Remove the shaft retaining ring using the snap ring
pliers J–8059.
7. Remove the tripot and the tripot joint retaining ring
from the axle shaft.
8. Remove the tripot joint seal from the axle shaft.

3B – 10IMANUAL TRANSAXLE DRIVE AXLE
DAEWOO V–121 BL4
Installation Procedure
Tools Required
J–8059 Snap Ring Pliers
J–35566 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 J–8059.
4. 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.
5. Install the boot to the joint housing.
6. Install a new large seal retaining clamp. Crimp the
large seal retaining clamp using the seal clamp pli-
ers J–35566.
7. Crimp the new small seal retaining clamp using the
seal clamp pliers J–35566.
8. Install the drive axle shaft to the vehicle. Refer to
”Drive Axle Assembly” in this section.

MANUAL TRANSAXLE DRIVE AXLE 3B – 11
DAEWOO V–121 BL4
CROSS GROOVE JOINT SEAL
Tools Required
J–35566 Seal Clamp Pliers
J–8059 Snap Ring Pliers
Removal Procedure
1. Remove the large seal retaing clamp.Discard the
clamp.
2. Remove the small seal retaining clamp. Discard the
clamp.
3. Degrease the joint.
4. Remove the shaft retaining ring using the snap ring
pilers J–8059.
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 per-
formance and safety.
6. Remove the seal from the joint assembly.
Installation Procedure
1. Install a new small seal retaining clamp onto the
seal. Do not crimp.
2. Install the seal onto the axle shaft.
3. Install the joint assembly onto the axle shaft.

3B – 12IMANUAL TRANSAXLE DRIVE AXLE
DAEWOO V–121 BL4
4. Install the shaft retaining ring using the snap ring
pilers J–8059.
5. 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.
6. Install the a new large seal retaining clamp.
7. Crimp the new large seal retaining clamp using the
seal clamp pliers J–35566.
8. Crimp the new small retaining clamp using the seal
clamp pliers J–35566.

MANUAL TRANSAXLE DRIVE AXLE 3B – 13
DAEWOO V–121 BL4
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 front–wheel as-
semblies. Each axle assembly consists of an innerconstant–velocity joint and an outer constant–velocity
joint connected to an axle shaft. The inner joint is com-
pletely 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.

HYDRAULIC BRAKES 4A – 11
DAEWOO V–121 BL4
6. Slowly push and hold the brake pedal one time.
7. Loosen the front brake line at the master cylinder to
purge air from the cylinder.
8. Tighten the brake line (as in step 5), and then re-
lease the brake pedal slowly. Wait 15 seconds be-
fore proceeding to the next step.
9. Repeat the sequence, including the 15–second
wait, until all the air is removed from the master
cylinder bore.
Notice : Care must be taken to prevent brake fluid from
contacting any painted surface to prevent damage to the
paint finish.
10. After all the air has been removed at the forward
connection(s), bleed the master cylinder at the rear
(cowl) connection(s) in the same manner as with
the front connections.
Important : For vehicles equipped with a non–antilock
braking system, the bleeding sequence is as follows: right
rear, left rear, left front and right front. For ABS vehicles,
refer to Section 4F, Antilock Brake System for the correct
sequence and bleeding procedure.
11. Attach a transparent tube over the valve. Allow the
tube to hang submerged in brake fluid in a transpar-
ent container.