2005 Chevrolet Aveo 2005 SUSPENSION Rear Suspension - Aveo 2005 SUSPENSION Rear Suspension - Aveo SPECIFICATIONS FASTENER TIGHTENING SPECIFICA’ Fastener Tightening Specificat Specification Application Metric English Rear Axle to Body Bracket Bolt 115 Nm 85 Ib ft Rear Axle Mounting Bracket Bolts 70 N.m 52 Ib ft Shock Absorber-to-Axle Bolt - Lower 722N.m 53 Ib ft Shock Absorber-to-Body Bolts - Upper 50N.m 37 Ib ft Wheel Hub and Bearing Assembly 40. Nm 30 Ib ft COMPONENT LOCATOR REAR SUSPENSION COMPONENTS.2005 Chevrolet Aveo 2005 SUSPENSION Rear Suspension - Aveo Fig. 1: Rear Suspension Components Courtesy of GENERAL MOTORS CORP. Callouts For Fig. 1 Callout Component Name 1 Shock Absorber Upper Bolt Spring Upper Insulator Coil Spring Spring Lower Insulator Wheel Bearing Spindle Brake Drum Caulking Nut 20|alafurfs|oo|ro Spindle Cap2005 Chevrolet Aveo 2005 SUSPENSION Rear Suspension - Aveo 9 Rear Axle 10 Shock Absorber Lower Bolt u Shock Absorber REPAIR INSTRUCTIONS TRIM HEIGHT INSPECTION PROCEDURE. Check excessive friction in the rear suspension as follows: 1. With the aid of a helper, lift up on the rear bumper and raise the vehicle as high as possible, Slowly release the bumper and allow the car to assume normal trim height. N Measure the distance from the floor to the center of the bumper. Push down on the bumper, release slowly, and allow the car to assume normal trim height. Measure the distance from the floor to the center of the bumper. w # The difference between the 2 measurements should be less than 12.7 mm (0.5 in). If the difference exceeds this limit, inspect the control arm for damage or wear. WHEEL BEARING/HUB REPLACEMENT - REAR 2: View of Drum From Spindle2005 Chevrolet Aveo 2005 SUSPENSION Rear Suspension - Aveo Courtesy of GENERAL MOTORS CORP. The rear wheel bearings are in the brake drum, Replace the wheel bearings and brake drum as an assembly. Refer to Brake Drum Replacement REAR AXLE LOWER CONTROL ARM BUSHING REPLACEMENT Tools Required + J 21474-01 Control Arm Bushing Set. See Special Tools « J 21474-18 Long Nut # 121474-19 Screw Assembly # 1 29376-7 Receiver Cap « J 29376-A Rear Control Arm Bushing Servicing Set. See Special Tools + KM-266-A Remover/Installer. See Special Tools \ssembly Procedure2005 Chevrolet Aveo 2005 SUSPENSION Rear Suspension - Aveo Fig. 3: Disassembly Procedure Courtesy of GENERAL MOTORS CORP. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information Remove the rear axle and secure the axle to a workbench. Refer to Rear Axle Replacement In order to remove the bushings, warm the rear axle in the area of the bushings to approximately 50-75°C (122-158°F) using an industrial hot air dryer. Using J 29376-A , place the housing (3) on the rear axle. See Special Tools Using J 21474-01 and J 29376-A , perform the following procedures: 1. Slide the J 21474-19 (2) through the J 29376-6-A bushing remover (1). 2. Slide the J 21474-19 through the rear control arm bushing 3. Slide the J 21474-19 through the J 29376-7 (4). 4, Install the J 21474-18 (5).2005 Chevrolet Aveo 2005 SUSPENSION Rear Suspension - Aveo . Partially remove the bushing by holding the J 21474-19 and turning the J 21474- 18 Remove the bushing completely by striking the J 29376-6-A bushing remover (1) with KM-266-A . See Special Tools Assembly Procedure Fig. 4: J 29376-A & J 21474-01 Courtesy of GENERAL MOTORS CORP. 1, Using J 29376-A and J 21474-01 , perform the following procedures 1 . Slide the J 21474-19 (1) through the thrust washer (6). . Slide the J 21474-19 through the J 29376-7 (5). . Slide the J 21474-19 through the bushing. en we Place the housing (4) on the rear axle. Slide the J 21474-19 through the J 29376-6-A bushing installer (3)2005 Chevrolet Aveo 2005 SUSPENSION Rear Suspension - Aveo 6. Install the J 21474-18 (2). 7. Hold the J 21474-19 and turn the J 21474-18 Fig. 5: Axis Of Rear Axle Courtesy of GENERAL MOTORS CORP. 2. Maintain a bushing angle of 45 degrees (a) to the axis of the rear axle. Install the rear axle. Refer to Rear Axle Replacement 4. Lower the vehicle. SHOCK ABSORBER REPLACEMENT Removal Procedure2005 Chevrolet Aveo 2005 SUSPENSION Rear Suspension - Aveo Fig. 6: Jack Stand Support Rear Axle Courtesy of GENERAL MOTORS CORP. NOTE: Remove only one shock at a time when both shocks are being replaced. Do not suspend the rear axle by the brake hoses. Damage to the brake hoses may result. 1, Remove the shock absorber-to-body bolts - upper. NOTE: Refer to Vehicle Lifting and Jacking Notice in Cautions and Notices. IMPORTANT: When lifting the vehicle with a body hoist, it will be necessary to support the rear axle with adjustable jack stands. 2. Raise the vehicle and support the rear axle assembly 3. Remove the lower shock absorber-to-axle bolt. 4, Remove the shock absorber. Installation Procedure2005 Chevrolet Aveo 2005 SUSPENSION Rear Suspension - Aveo Fig. 7: Lower Shock Absorber-To-Axle & Bolt Courtesy of GENERAL MOTORS CORP. IMPORTANT: It will be necessary to bring the axle assembly to trim height prior to tightening the shock absorber attachment bolts. 1. Insert the lower shock absorber-to-axle bolt through the shock absorber lower attachment bracket and into the axle. NOTE: Refer to Fastener Notice in Cautions and Notices. 2. Lower the vehicle enough to guide the upper shock stud on the body opening and2005 Chevrolet Aveo 2005 SUSPENSION Rear Suspension - Aveo loosely install the attaching bolts. Tighten: « Tighten the lower shock absorber-to-axle bolt to 72 N.m (53 Ib ft) « Tighten the upper shock absorber-to-body bolt to 50 N.m (37 Ib ft) COIL SPRING REPLACEMENT Removal Procedure Fig. 8: Jack Stand Support Rear Control Arms Courtesy of GENERAL MOTORS CORP. CAUTION: When removing the rear springs, do not use a twin- post type hoist. The swing arch tendency of the rear axle assembly when certain fasteners are removed may cause it to slip from the hoist which may cause personal injury.2005 Chevrolet Aveo 2005 SUSPENSION Rear Suspension - Aveo 1 4 NOTE: Refer to Vehicle Lifting and Jacking Notice in Cautions and Notices. Raise and suitably support the vehicle, Use a frame contact hoist if possible and support the rear control arms with jack stands. If it becomes necessary to lift the vehicle with a twin-post hoist, lift the body and support the control arms with jack stands. Remove the wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. Remove the right and the left shock absorber bolts. Refer to Shock Absorber Replacement Lower the rear axle and remove the springs and the top insulator Installation Procedure2005 Chevrolet Aveo 2005 SUSPENSION Rear Suspension - Aveo 1 Fig. 9: Upper Insulator & Lower Bumper Courtesy of GENERAL MOTORS CORP. IMPORTANT: Prior to installing the springs, it will be necessary to install the upper insulators to the body and adhesive to keep them in position while raising the axle assembly and the springs. Install the upper insulator and seat the lower bumper.2005 Chevrolet Aveo 2005 SUSPENSION Rear Suspension - Aveo Fig. 10: Jack Stand Support Rear Control Arms Courtesy of GENERAL MOTORS CORP. 2. Install the springs and raise the axle. Install the shock absorbers. Refer to Shock Absorber Replacement IMPORTANT: It will be necessary to bring the axle assembly to trim height prior to tightening the shock absorber attachment bolts. 4. Install the wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. 5. Remove the jack stands and lower the vehicle. REAR AXLE OVERHAUL (WITHOUT ABS) Disassembly Procedure 1. Remove the rear axle. Refer to Rear Axle Replacement2005 Chevrolet Aveo 2005 SUSPENSION Rear Suspension - Aveo Remove the hub and bearing assembly. Remove the spindle from the rear axle. Refer to Wheel Bearing/Hub Replacement - Rear Remove the rear brake assembly. Refer to Drum Brake Backing Plate Replacement in Drum Brakes. Remove the stabilizer shaft. Refer to Stal Suspension izer Shaft Replacement in Front Remove the rear control arm bushings. Refer to Rear Axle Lower Control Arm Bushing Replacement Assembly Procedure 1 6. 7 Install the rear control arm bushings. Refer to Rear Axle Lower Control Arm Bushing Replacement Install the stabilizer shaft. Refer to Stabilizer Shaft Replacement in Front Suspension. Install the rear brake assembly. Refer to Drum Brake Backing Plate Replacement Thinly coat the wheel spindle with antifriction bearing grease in the area of the brake anchor plate. Install the spindle and the hub and bearing assembly. Refer to Wheel Bearing/Hub Replacement - Rear Install the rear axle. Refer to Rear Axle Replacement Adjust the wheel bearing, REAR AXLE OVERHAUL (WITH ABS) Disassembly Procedure Remove the rear axle. Refer to Rear Axle Replacement Remove the hub and bearing assembly. Refer to Wheel Bearing/Hub Replacement - Rear. Remove the rear brake assembly. Refer to Drum Brake Backing Plate Replacement Remove the stabilizer shaft. Refer to Stabilizer Shaft Replacement in Front Suspension Remove the rear control arm bushings. Refer to Rear Axle Lower Control Arm Bushing Replacement Assembly Procedure 1 N Install the rear control arm bushings. Refer to Rear Axle Lower Control Arm Bushing Replacement Insert the stabilizer shaft into the new rear axle and screw the shaft into place. Refer to Stabilizer Shaft Replacement in Front Suspension Install the rear brake assembly Refer to Drum Brake Backing Plate Replacement2005 Chevrolet Aveo 2005 SUSPENSION Rear Suspension - Aveo 4, Install the hub and bearing assembly. Refer to Wheel Bearing/Hub Replacement - Rear 5. Install the rear axle. Refer to Rear Axle Replacement REAR A -E REPLACEMENT Removal Procedure Fig. 11; Jack Stand Support Rear Axle Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Vehicle Lifting and Jacking Notice in Cautions and Notices. 1. Raise and suitably support the vehicle 2. Remove the rear wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. 3. Disconnect the parking brake. Refer to Park Brake Cable Replacement in Parking Brake. 4. Disconnect the ABS sensor line.2005 Chevrolet Aveo 2005 SUSPENSION Rear Suspension - Aveo Fig. 12: Brake Pipes, Brake Hoses & Rear Axle Brackets Courtesy of GENERAL MOTORS CORP. 5. Disconnect the brake pipes from the brake hoses at the rear axle brackets by removing the cap screws and the retaining clip. Cap or tape the brake hose openings to prevent entry of foreign matter. Unclip the brake hose from the rear axle brackets. Refer to Brake Hose Replacement - Rear In Hydraulic Brakes. 6. Place support jacks under the arms of the rear axle and raise the rear axle arms slightly Remove the shock absorbers. Refer to Shock Absorber Replacement . 7, Remove the shock absorbers. Refer to Shock Absorber Replacement . 8. Lower the support jacks and remove the rear springs. Refer to Coil Spring Replacement 9, Remove the left rear axle mounting bolts and the right rear axle mounting bracket bolts from the underbody. Pry the rear axle slightly with a screw-driver, if required. 10. Remove the rear axle. Inetallation Procedure.2005 Chevrolet Aveo 2005 SUSPENSION Rear Suspension - Aveo Nv » CAIDAS Fig. 13: Underbody Mountings, Rear Axle-To-Body Bracket & Bolt Courtesy of GENERAL MOTORS CORP. Raise the rear axle and loosely fasten it to the vehicle underbody mountings with the rear axle-to-body bracket bolt Install the rear springs and insulators, Refer to Coil Spring Replacement . Raise the rear axle arm with the support jacks. Attach the shock absorber to the axle with the lower attachment bolt. Refer to Shock Absorber Replacement Connect the brake pressure hoses into the bracket on the rear axle. Mount the retaining clips. Connect the brake pipes to the brake hoses. Bleed the brakes. Refer to Brake Hose Replacement - Rear in Hydraulic Brakes. ee Tnctall the narkine brake Refer to Park Rrake Lever Accemhly Ren!2005 Chevrolet Aveo 2005 SUSPENSION Rear Suspension - Aveo Parking Brake Fig. 14: Brake Pipes, Brake Hoses & Rear Axle Brackets Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Vehicle Lifting and Jacking Notice in Cautions and Notices. 9. Lower the vehicle slightly and install the rear wheels, Refer to Tire and Wheel Removal and Installation in Tires and Wheels. NOTE: Refer to Fastener Notice in Cautions and Notices. 10, At curb height, tighten the left rear axle-to-body bracket bolt and the right rear axle mounting bracket bolts2005 Chevrolet Aveo 2005 SUSPENSION Rear Suspension - Aveo 1 Tighten: « Tighten the rear axle-to-body bracket bolt to 115 N.m (85 Ib ft) « Tighten the rear axle mounting bracket bolts to 70 N.m (52 Ib fi). Adjust the rear wheel brakes. Bleed the brake system and check for leaks. Refer to Hydraulic Brake System Bleeding (Manual) or Hydraulic Brake System Bleeding (Pressure) in Hydraulic Brakes Fig. 15: Jack Stand Support Rear Axle Courtesy of GENERAL MOTORS CORP. 12. Connect the ABS sensor line 13. Adjust the parking brake. Refer to Park Brake Adjustment in Parking Brake. 14, Lower the vehicle completely DESCRIPTION AND OPERATION REAR SUSPENSION DESCRIPTION AND OPERATION, The rear suspension consists of an axle with trailing arms and a twisting cross beam, 2 coil springs, 2 shock absorbers, 2 upper spring insulators, and 2 spring compression bumpers2005 Chevrolet Aveo 2005 SUSPENSION Rear Suspension - Aveo The axle support assembly attaches to the underbody through a rubber bushing located at the front of each of the control arms. The brackets are integral with the underbody side rails. The axle structure maintains the relationships of the wheels to the body. A serviceable stabilizer shaft, incorporated with the axle beam, attaches to each of the control arms. Each coil spring is retained between a seat in the underbody and a seat welded to the top of the rear axle control arm. The coil spring lower end rests on a compression bumper in the welded bracket on top of the rear axle, while a rubber insulator is used to isolate the coil spring upper end from the vehicle underbody seat. SPECIAL TOOLS AND EQUIPMENT SPECIAL TOOLS Special Tools Illustration Tool Number/ Description co KM 266-A Remover / Installer J21474-01 Control Arm Bushing Set % & J29376-A Spt OQ Rear Control Arm Bushing Service Set