My 07 Aveo is out of warranty by about 6000 miles, so I have to pay $500 for a whole rear axle just to replace the bad bushing. This should be a recall, as it is a safety issue because those bushings help stabilize the rear of the vehicle over bumps.
I've thoughht about any other possibilities and options when it comes to this bushings.....what about getting the measurements (width, lentgh, diameter. ). With that said, well be able to look for a same bushing in a different car's make and model that could be similar in sizes. I found some bushings on www.napaonline.com but the ones offered by them are a little too bug or small compared to the ones for the aveo..........!
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NOW. These cars are notorious for timing belts snapping and GM has advised to replace at 60K. I have this car and it has an interference engine, meaning that if the belt snaps there is a good chance the engine's pistons will bend the intake/exhaust valves, meaning you would have to have the engine rebuilt if this happens.
I am about to have mine changed, along with the water pump and tensioner since the water pump should be replaced before 100,000 and involves the same labor. I've found that at a Chevy dealership the whole package ranges from $500-$800 depending on who you call.
Though it seems that you have the car that needs everything, I am fairly certain that lemon law requires that a particular single problem needs multiple repairs and after that, problem is still not resolved, but it may also apply to you. If the repairs were all warranty items, that may change things as well. The one item that "sticks out" as I read this is the two cat replacements...this is extremely unusual unless there is an unresolved engine problem, or, your dealer is "pumping up" their warranty claims to the manufacturer for some reason. Best place to find what you need to know is the consumer protection agency in your state, or, DMV. Hope it's running well now...you have lots of new parts!
I have the same problem with 06 Aveo the trunk door has broke on me three times the dealership told me the lever that opens it breaks well i had them fix it the first time cost me $100 then the second time they wanted me to pay $500 to install a whole new thing my husband glued it back together that lasted a little while then a friend looked at it and there is a little green piece that the bar goes into that is the part that breaks but sometimes they just don't assemble it right and thats what it was in my case so check that green piece and trade the pos in thats what I plan to do with mine the airbags malfunction two months after i get them fixed every time my advice never buy an Aveo!
just go to any junk yard and find a used deawoo lanos and pull the head if timing belt was not broke, if it looks good, its a exact fit 100%, no special tools needed, just normal wrench set and torqe wrench. after head is installed, get a gates timing belt only.
My 2004 had the same problem at 102,000 kms, warranty was up at 100,000 kms. GM would not do a thing and was very rude about it. I figured at 4 years old, I should not need a whole new axle, but the bushings are not separate from the axle, so the whole axle had to be replaced. I found a fairly new axle (from a 2006 with only 16,000 kms on it) at a salvage place for $350 (would have been $500 new at the dealership). They scrap the vehicles and sell the parts, try one of those, you may get it much cheaper.
At 60,000 you should have all the major things done if you haven't already:
oil change(every 3000)
air filter change(every 15,000)
coolant flush(every 30,000)
spark plugs and wires(every 30,000)
transmission fluid & filter change(every 30,000)
brakes (as needed)
PCV valve (every 20,000)
You can wait until about 75000 miles to do your timing belt.