Chevrolet Sonic Repair Manual: Gears Cleaning and Inspection (Gen 1)

Chevrolet Sonic Repair Manual / Powertrain / Transmission/Transaxle / Manual / General / Gears Cleaning and Inspection (Gen 1)

Gears

Warning:

Wear safety glasses to avoid injury when using compressed air or any cleaning solvent. Bodily injury may occur if fumes are inhaled or if skin is exposed to chemicals.

Clean the following gears in a suitable solvent and air dry all the parts.

1st gear (1)
2nd gear assembly (4)
3rd gear assembly (3)
4th gear assembly (2)
Reverse idler gear (5)

Inspect the gear tooth surfaces on all the gears for the following conditions:

Cracks
Pitting
Nicks
Chipped gear teeth
High spots ?small shiny spots on the gear teeth mating surfaces

Input Shaft

Clean the input shaft (1) in a suitable solvent.
Clean and air dry the oil gallery.
Inspect the input shaft bearing surfaces for the following conditions:

Wear
Lack of lubricant
Debris embedded in the oil grooves
Brinelling

Inspect the input shaft splines for wear or damage.

Replace the input shaft if any of the above conditions are found.

Main Shaft

Clean the main shaft (1) in a suitable solvent.
Clean and air dry the oil gallery.
Inspect the main shaft bearing surfaces for the following conditions:

Wear
Lack of lubricant
Debris embedded in the oil grooves
Brinelling

Inspect the main shaft splines for wear or damage.

Replace the main shaft if any of the above conditions are found.

Reverse Idler Gear and Shaft

Clean the reverse idler gear (1) and shaft (2) in

Clean the reverse idler gear (1) and shaft (2) in a suitable solvent and air dry all the parts.
Inspect the reverse idler gear bushing (3) for the following conditions:

Excessive wear
Scoring
Pitting

Replace the reverse idler gear if the bushing is faulty.

Inspect the reverse idler gear shaft for the following conditions:

Excessive wear
Scoring
Pitting

Replace the reverse idler gear shaft if it is faulty.

Gear Position Sensor Replacement

Gear Position Sensor Replacement Callout Component Name Preliminary Procedure Unclip the engine control module (ECM) and bracke ...

Gears Cleaning and Inspection (Gen 2)

Gears Warning: Wear safety glasses to avoid injury when using compressed air or any cleaning solvent. Bodily injury may occur if fumes are inhaled or if skin is exp ...

Other materials:

Connecting and Controlling a USB Drive
The infotainment system can only play back.mp3 and.wma files from a USB drive. Only the first 2,500 songs are recognized on the device. When a device is not supported, the message “No supported data found. You can safely disconnect the device” appears. Connecting a USB Drive Connect the US ...

Front Seat Back Recliner Handle Replacement
Front Seat Back Recliner Handle Replacement Callout Component Name 1 Front Seat Recliner Handle Cover Cap Procedure Use a flat-bladed tool to release the handle cover from the handle assembly. ...

Piston and Connecting Rod Assemble
Special Tools EN-49941 Remover / Installer Piston Retainer Ring For equivalent regional tools, refer to Special Tools. Note: Lubricate the piston pin with clean engine oil. Install the connecting rod (3) and the piston pin (2) to the piston (1). Install t ...

0.0095