2004 DAEWOO LACETTI Rod

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.

3A – 6IAUTOMATIC TRANSAXLE DRIVE AXLE
DAEWOO V–121 BL4
6. 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).
7. 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).
8. Loosely install a new axle shaft caulking nut. Al-
ways use a new nut.
9. Install the wheels. Loosely install the nuts. Refer to
Section 2E, Tires and Wheels.
10. Lower the vehicle to the floor.
Tighten
Tighten the wheel nuts to 100 NSm (74 lb–ft).
11. Tighten the axle shaft caulking nut to 300 NSm (221
lb–ft).
12. Peen the caulking nut with a punch and a hammer
until the nut is locked into place on the axle shaft
hub.
13. Refill the transaxle fluid to the proper level. Refer to
Section 5A, ZF 4HP 16 Automatic 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–