Front Suspension System: Removal & Installation Chevrolet Sonic I

Removal Procedure

1. Remove the intermediate steering shaft lower bolt. Refer to «Intermediate Steering Shaft Replacement»(ref-542491-S38156966972013041600000) .
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-542467-S12591948612013041600000) .
3. Remove the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(ref-542477-S14282548822013041600000) .
4. Remove the front wheelhouse inner liner front extension. Refer to «Front Wheelhouse Liner Inner Front Extension Replacement (Left SIde)»(ref-542501-S19650633952013041600000) , «Front Wheelhouse Liner Inner Front Extension Replacement (Right Side, LUV)»(ref-542501-S38358154662013041600000) , «Front Wheelhouse Liner Inner Front Extension Replacement (Right SIde, LWE, LUW)»(ref-542501-S42421321842013041600000) .
5. Remove the front bumper impact bar lower bracket. Refer to «Front Bumper Impact Bar Lower Bracket Replacement»(ref-542484-S10324037482013041600000) .
6. Remove the stabilizer shaft links from the stabilizer shaft. Refer to «Stabilizer Shaft Link Replacement»(ref-542507-S36574645822013041600000) .
7. Remove the lower control arm ball joint bolt and nut from the steering knuckle. Refer to «Lower Control Arm Replacement»(ref-542507-S14574837192013041600000) .
8. Disconnect the steering linkage tie rod end from the steering knuckle. Refer to «Steering Linkage Outer Tie Rod Replacement»(ref-542506-S19624889452013041600000) .
9. Remove the transmission rear mount to bracket retaining bolt. Refer to «Transmission Mount Bracket Replacement - Rear»(ref-542509-S28132196082013041600000) .
10. Remove the exhaust pipe insulators (1).
11. Release the front suspension frame front bolts about 10 mm.
12. Using a suitable support, support the crossmember area of the cradle.
13. Using a suitable support, lower the front suspension frame (1) about 500 mm enough to gain access to the stabilizer shaft insulator bolts and to remove the stabilizer shaft. Refer to «Drivetrain and Front Suspension Frame Replacement»(ref-542501-S18818633002013041600000)
14. Remove the stabilizer shaft insulator bolts (1).
15. Remove the front stabilizer shaft (1) from the front suspension frame.

Installation Procedure

1. Position the front stabilizer shaft (1) in the front suspension frame.
2. Install the front stabilizer shaft insulator bolts (1) and tighten to 22 N.m (16 lb ft).
3. Lift the front suspension frame (1) into the proper position and tighten the front suspension frame bolts. Refer to «Drivetrain and Front Suspension Frame Replacement»(ref-542501-S18818633002013041600000) .
4. Install the transmission rear mount to bracket retaining bolt. Refer to «Transmission Mount Bracket Replacement - Rear»(ref-542509-S28132196082013041600000)
5. Connect the steering linkage tie rod end from the steering knuckle. Refer to «Steering Linkage Outer Tie Rod Replacement»(ref-542506-S19624889452013041600000)
6. Install the lower control arm ball joint to steering knuckle bolts. Refer to «Lower Control Arm Replacement»(ref-542507-S14574837192013041600000) .
7. Install the stabilizer shaft link to the stabilizer shaft. Refer to «Stabilizer Shaft Link Replacement»(ref-542507-S36574645822013041600000) .
8. Install the exhaust pipe insulators (1).
9. Install the front bumper impact bar lower bracket. Refer to «Front Bumper Impact Bar Lower Bracket Replacement»(ref-542484-S10324037482013041600000) .
10. Install the front wheelhouse inner liner front extension. Refer to «Front Wheelhouse Liner Inner Front Extension Replacement (Left SIde)»(ref-542501-S19650633952013041600000) , «Front Wheelhouse Liner Inner Front Extension Replacement (Right Side, LUV)»(ref-542501-S38358154662013041600000) , «Front Wheelhouse Liner Inner Front Extension Replacement (Right SIde, LWE, LUW)»(ref-542501-S42421321842013041600000) .
11. Install the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(ref-542477-S14282548822013041600000) .
12. Remove the support and lower the vehicle.
13. Install the intermediate steering shaft lower bolt. Refer to «Intermediate Steering Shaft Replacement»(ref-542491-S38156966972013041600000) .

Scheme 5

Stabilizer Shaft Link Replacement

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-542467-S12591948612013041600000) .
2. Remove the steering knuckle assembly from the vehicle. Refer to «Steering Knuckle Replacement»(ref-542507-S38587192992013041600000) .
3. Position the steering knuckle assembly (1) in a suitable vise.
4. Position the CH-50059-1 wheel hub/bearing removal/installation bridge assembly (1) and the CH-50559-2 wheel hub/bearing removal/installation adapter (2) on the wheel bearing inner hub.
5. Using the CH-50059-1 and the CH-50559-2 , remove the wheel hub from the wheel bearing.
6. If the inner race of the bearing is pulled out with the hub, remove the inner race from the using the appropriate tools (1, 2).
7. Using the appropriate tool, remove the retaining ring (1) from the steering knuckle.
8. Position the CH-50559-1 wheel hub/bearing removal/installation bridge assembly (1) and the CH-50559-3 wheel bearing removal adapter (2) on the steering knuckle.
9. Remove the wheel bearing from the steering knuckle and discard it. Inspect the bore of the of the steering knuckle for pitting, scoring wear, or corrosion. If damage cannot be easily cleaned up with light sanding, replace the steering knuckle.

1. Using the CH-50559-4 wheel hub/bearing installation adapter (1) and the appropriate extension and press, install the new bearing into the steering knuckle until it is correctly seated.
2. Position the CH-50559-4 (1) wheel hub/bearing installation adapter and the appropriate extension to the inside of the bearing and position the CH-50559-2 wheel hub removal/installation adapter and the appropriate extension on the wheel hub.
3. Press in the hub until it is correctly seated.
4. Using the appropriate tool, install the retaining ring (1).
5. Verify the hub rotates smoothly.
6. Install the steering knuckle assembly in the vehicle. Refer to «Steering Knuckle Replacement»(ref-542507-S38587192992013041600000) .
7. Lower the vehicle.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-542467-S12591948612013041600000) .
2. Remove the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(ref-542477-S14282548822013041600000) .
3. Remove the wheel speed sensor from the steering knuckle. Refer to «Front Wheel Speed Sensor Replacement»(ref-542519-S00873966802013041600000) .
4. Separate the wheel drive shaft from the steering knuckle. Refer to «Front Wheel Drive Shaft Replacement»(ref-542524-S06936399752013041600000) .
5. Remove the brake rotor from the steering knuckle. Refer to «Front Brake Rotor Replacement»(ref-542520-S03314319892013041600000) .
6. Remove the front brake dust shield bolts (2) and the shield (1).
7. Remove the lower ball joint bolt and nut from the steering knuckle. Refer to «Lower Control Arm Replacement»(ref-542507-S14574837192013041600000) .
8. Remove the bolts (2) and the nuts (1) from the front strut to the steering knuckle. Refer to «Strut Assembly Removal and Installation»(ref-542507-S13420747762013041600000)
9. Remove the steering knuckle assembly (1) from the vehicle.
10. Remove the wheel bearing and hub assembly from the steering knuckle. Refer to «Front Wheel Bearing and Hub Replacement»(ref-542507-S26391678722013041600000) .

1. Install the wheel bearing and hub assembly in the steering knuckle. Refer to «Front Wheel Bearing and Hub Replacement»(ref-542507-S26391678722013041600000) .
2. Position the steering knuckle (1) in the front strut and lower ball joint.
3. Install the bolts (2) and the nuts (1) from the front strut assembly to the steering knuckle. Refer to «Strut Assembly Removal and Installation»(ref-542507-S13420747762013041600000) .
4. Install the lower ball joint bolt and nut to the steering knuckle. Refer to «Lower Control Arm Replacement»(ref-542507-S14574837192013041600000) .
5. Install the front brake dust shield (1) bolts (2) and the bolts to 9 N.m (80 lb in).
6. Install the brake rotor on the steering knuckle. Refer to «Front Brake Rotor Replacement»(ref-542520-S03314319892013041600000) .
7. Install the NEW wheel drive shaft nut. Refer to «Front Wheel Drive Shaft Replacement»(ref-542524-S06936399752013041600000) .
8. Install the wheel speed sensor in the steering knuckle. Refer to «Front Wheel Speed Sensor Replacement»(ref-542519-S00873966802013041600000) .
9. Install the tire and wheel assembly the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(ref-542477-S14282548822013041600000) .
10. Remove the supports and lower the vehicle.
11. Check the front wheel alignment measurements, if the vehicle had a camber adjustment repair. Refer to «Wheel Alignment Specifications»(ref-542573-S10595292482013041600000) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-542467-S12591948612013041600000) .
2. Remove the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(ref-542477-S14282548822013041600000) .
3. Remove the front wheelhouse rear liner. Refer to «Front Wheelhouse Liner Replacement (Rear)»(ref-542501-S10783180022013041600000) , «Front Wheelhouse Liner Replacement (Front)»(ref-542501-S05403905302013041600000) .
4. Remove the front wheelhouse liner inner front extension. Refer to «Front Wheelhouse Liner Inner Front Extension Replacement (Left SIde)»(ref-542501-S19650633952013041600000) , «Front Wheelhouse Liner Inner Front Extension Replacement (Right Side, LUV)»(ref-542501-S38358154662013041600000) , «Front Wheelhouse Liner Inner Front Extension Replacement (Right SIde, LWE, LUW)»(ref-542501-S42421321842013041600000) .
5. Disconnect the steering linkage tie rod end from the steering knuckle. Refer to «Steering Linkage Outer Tie Rod Replacement»(ref-542506-S19624889452013041600000) .
6. Remove the lower ball joint nut (1) and bolt (2).
7. Remove and discard the front lower control bolt (1). Replace with NEW only.
8. Remove the front lower control arm rear nut (1) and bolt (2).
9. Push the front brake corner forward and then remove the front lower control arm (1).

1. Push the front brake corner forward and then position the lower control arm (1) in the vehicle.
2. Install the NEW front lower control arm front bolt (1) and tighten to. First Pass: 115 N.m (85 lb ft) Final Pass: plus 65 degrees
3. Tighten the NEW front lower control arm rear nut (1) to: First Pass: 160 N.m (118 lb ft) Final Pass: plus 35 degrees
4. Install the NEW lower ball joint bolt (2) and nut (1) and tighten the to nut (1): First Pass: 30 N.m (22 lb ft) Second Pass: release 120 degrees Third Pass: 30 N.m (22 lb ft) Final Pass: plus 35 degrees
5. Install the steering linkage tie rod end on the steering knuckle. Refer to «Steering Linkage Outer Tie Rod Replacement»(ref-542506-S19624889452013041600000) .
6. Install the front wheelhouse liner inner front extension. Refer to «Front Wheelhouse Liner Inner Front Extension Replacement (Left SIde)»(ref-542501-S19650633952013041600000) , «Front Wheelhouse Liner Inner Front Extension Replacement (Right Side, LUV)»(ref-542501-S38358154662013041600000) , «Front Wheelhouse Liner Inner Front Extension Replacement (Right SIde, LWE, LUW)»(ref-542501-S42421321842013041600000) .
7. Install the front wheelhouse rear liner. Refer to «Front Wheelhouse Liner Replacement (Rear)»(ref-542501-S10783180022013041600000) , «Front Wheelhouse Liner Replacement (Front)»(ref-542501-S05403905302013041600000) .
8. Install the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(ref-542477-S14282548822013041600000) .
9. Lower the vehicle.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-542467-S12591948612013041600000) .
2. Remove the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(ref-542477-S14282548822013041600000) .
3. Without disconnecting the hydraulic brake flex hose, remove and support the brake caliper and bracket as an assembly. Refer to «Front Brake Rotor Replacement»(ref-542520-S03314319892013041600000) .
4. Remove the front wheel hub. Refer to «Front Wheel Bearing and Hub Replacement»(ref-542507-S26391678722013041600000) .
5. Using the CH 43631 separator (2), remove the wheel stud (1) from the wheel bearing and hub.

1. Install a NEW wheel stud to the wheel hub flange (2).
2. Position three washers (3) and an old lug nut (1) on the stud to be replaced.
3. Position the pry bar to hold the wheel bearing flange while tightening the wheel lug nut.
4. Tighten the old lug nut (1) until the wheel stud is firmly seated in the wheel hub flange.
5. Remove the washers (3) and the old lug nut (1) and the pry bar.
6. Install the front wheel hub. Refer to «Front Wheel Bearing and Hub Replacement»(ref-542507-S26391678722013041600000) .
7. Install the front brake rotor. Refer to «Front Brake Rotor Replacement»(ref-542520-S03314319892013041600000) .
8. Install the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(ref-542477-S14282548822013041600000) .
9. Lower the vehicle.

1. Remove the air inlet grille panel. Refer to «Air Inlet Grille Panel Replacement»(ref-542492-S18360867622013041600000) .
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-542467-S12591948612013041600000) .
3. Remove the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(ref-542477-S14282548822013041600000) .
4. Remove the stabilizer shaft link from the front strut assembly. Refer to «Stabilizer Shaft Link Replacement»(ref-542507-S36574645822013041600000) .
5. Remove the front brake hose (1) from the front strut assembly.
6. Remove the speed sensor wring harness from the front strut assembly, if needed.
7. Remove the outer tie rod end from the steering knuckle. Refer to «Steering Linkage Outer Tie Rod Replacement»(ref-542506-S19624889452013041600000) .
8. Support the lower control arm with a jack stand.
9. Remove the front strut nut (1) and the bolt (2) from the front strut.
10. Using the CH 49375 socket (2) and the proper size Torx® wrench, loosen the front strut nut.
11. Remove the front strut nut (1) and the retaining plate (2).
12. Remove the front strut assembly from the vehicle (1).
13. If removing the front strut assembly to service any of the front strut components, refer to «Strut, Strut Component, or Spring Replacement»(ref-542507-S25532541252013041600000) .

1. Position the front strut assembly (1) in the vehicle.
2. Install the front strut nut (1) and the retaining plate (2).
3. Using the CH 49375 socket (2) and the proper size Torx® wrench to hold the strut shaft, tighten the nut to 65 N.m (48 lb ft).
4. Install the front strut nut (1) and the bolt (2) from the front strut and tighten the nut to 110 N.m (82 lb ft).
5. Install the stabilizer shaft link in the front strut assembly. Refer to «Stabilizer Shaft Link Replacement»(ref-542507-S36574645822013041600000) .
6. Remove the jack stand from the lower control arm.
7. Install the outer tie rod end in the steering knuckle. Refer to «Steering Linkage Outer Tie Rod Replacement»(ref-542506-S19624889452013041600000) .
8. Install the speed sensor wiring harness on the front strut assembly, if needed.
9. Install the front brake hose (1) on the front strut assembly.
10. Install the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(ref-542477-S14282548822013041600000) .
11. Remove the support and lower the vehicle.
12. Install the air inlet grille panel. Refer to «Air Inlet Grille Panel Replacement»(ref-542492-S18360867622013041600000) .