Chevrolet Sonic Repair Manual: Rear Axle Replacement

Chevrolet Sonic Repair Manual / Chassis / Suspension / Rear Axle Replacement

Removal Procedure

Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
Remove the tires and wheel assembly. Refer to Tire and Wheel Removal and Installation.
Remove the park brake cables from the rear axle. Refer to Parking Brake Cable Replacement.

Note:

Cap the rear brakes lines so as to prevent the hydraulic brake system from being contaminated.

Remove the rear brake line from the rear axle. Refer to Brake Pipe Replacement.

Note:

Relocate the rear brake assembly to the side using mechanics wire.

Remove the rear wheel bearing/hub from the rear axle. Refer to Rear Wheel Bearing and Hub Replacement.
Using a hydraulic jack stand, support the rear axle assembly.

Using a bright colored paint, mark (1) the outline of the rear axle mounting bracket to the chassis to properly align the rear axle to the chassis for installation.

Note:

Before removing the spring and insulator's, note the relationship of the spring and insulators to the body and the rear axle.

Lower the rear axle and remove the rear springs and the insulators. Refer to Rear Spring, Insulator, and Jounce Bumper Replacement.

Note:

DO NOT remove the rear axle mounting bolts at this time.

Loosen the mounting bolts (1) for the rear axle.
With the aide of an assistant, remove the mounting bolts.

With the mounting bolts removed, lower the rear axle assembly (1).

Installation Procedure

Using a hydraulic jack stand and the aide of an assistant, position

Using a hydraulic jack stand and the aide of an assistant, position the rear axle assembly (1) in the vehicle.

Align the mounting points of the rear axle to the painted outline (1) on the chassis.

Caution:

Refer to Fastener Caution.

Install the rear axle mounting bolts (1) and tighten to:

First Pass: 160 Y (118 lb ft)
Final Pass: plus 30 degrees

Note:

Ensure that the rear springs and insulators are properly aligned seated in the rear axle.

Install the rear spring and the insulators. Refer to Rear Spring, Insulator, and Jounce Bumper Replacement.

Install the rear wheel bearing/hub mounting bolts to the rear axle. Refer to Rear Wheel Bearing and Hub Replacement.

Install the rear park brake cables. Refer to Parking Brake Cable Replacement.

Install the rear brake lines on the rear axle. Refer to Brake Pipe Replacement.

Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding.

Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.

Remove the supports and lower the vehicle.

Front and Rear Suspension Modification Kit Installation

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Rear Suspension Description and Operation

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Other materials:

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Point-to-point measurements are for reference only. All measurements are given in millimeters. Use these measurements for diagnosing and estimating. Point-to-point measurements are duplicated with tram bar pointers set at equal lengths. All die marks, holes, slots, and fasteners are measured t ...

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