2004 DAEWOO LACETTI transaxle

3A – 10IAUTOMATIC TRANSAXLE DRIVE AXLE
DAEWOO V–121 BL4
GENERAL DESCRIPTION
AND SYSTEM OPERATION
FRONT DRIVE AXLE
General Description
Drive axles are flexible shaft assemblies that transmit
rotational force from the transaxle to the front–wheel as-
semblies. Each axle assembly consists of an inner and anouter constant–velocity 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 can-
not move in and out.
The drive axles use one type of outboard joint and one type
of inboard joint. The inboard ends of both drive axles incor-
porate a female spline that installs over a stub shaft pro-
truding from the transaxle.

SECTION : 3B
MANUAL TRANSAXLE DRIVE AXLE
TABLE OF CONTENTS
SPECIFICATIONS3B–1 . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 3B–1. . . . . . . . . .
SPECIAL TOOLS3B–2 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools Table 3B–2. . . . . . . . . . . . . . . . . . . . . . . .
COMPONENT LOCATOR3B–2 . . . . . . . . . . . . . . . . . . . .
Front Drive Axle 3B–2. . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE AND REPAIR3B–5 . . . . . . . . . . . . . . .
ON–VEHICLE SERVICE 3B–5. . . . . . . . . . . . . . . . . . . . . Drive Axle Assembly 3B–5. . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR 3B–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outer Joint Seal 3B–8. . . . . . . . . . . . . . . . . . . . . . . . . .
Inner Tripot Seal 3B–9. . . . . . . . . . . . . . . . . . . . . . . . . .
Cross Groove Joint Seal 3B–11. . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION3B–13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Drive Axle 3B–13. . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb–FtLb–In
Axle Shaft Caulking Nut300221–
Lower Ball Joint Pinch Bolt and Nut6044–
Tie Rod Nut5541–
Wheel Nuts10074–

3B – 2IMANUAL TRANSAXLE DRIVE AXLE
DAEWOO V–121 BL4
SPECIAL TOOLS
SPECIAL TOOLS TABLE
J–8059
Snap Ring Pliers
KM–507–B
Ball Joint Remover
KM–460–A
Axle Shaft Remover
J–35566
Seal Clamp Pliers
COMPONENT LOCATOR
FRONT DRIVE AXLE

MANUAL TRANSAXLE DRIVE AXLE 3B – 3
DAEWOO V–121 BL4
1. Caulking Nut
2. C/V Joint
3. Axle Shaft
4. Seal Retaining Clamp
5. Drive Axle Outboard Seal
6. Seal Retaining Clamp7. Seal Retaining Clamp
8. Drive Axle Inboard Seal
9. Seal Retaining Clamp
10. Race Retaining Ring
11. Cross Groove Joint
12. Retaining Ring

3B – 4IMANUAL TRANSAXLE DRIVE AXLE
DAEWOO V–121 BL4
1. C/V Joint Assembly
2. C/V Joint
3. Seal Retaining Clamp
4. Drive Axle Outboard Seal
5. Seal Retaining Clamp
6. Axle Shaft7. Seal Retaining Clamp
8. Drive Axle Inboard Seal
9. Seal Retaining Clamp
10. Tripot Housing
11. Snap Ring
12. Tripot Joint Assembly

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.