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:

Tire Pressure Monitor System
The Tire Pressure Monitor System (TPMS) uses radio and sensor technology to check tire pressure levels. The TPMS sensors monitor the air pressure in your tires and transmit tire pressure readings to a receiver located in the vehicle. Each tire, including the spare (if provided), should be check ...

Windshield Wiper System Module Replacement
Windshield Wiper System Module Replacement Callout Component Name Preliminary Procedures Open and support the hood assembly. Remove the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement. ...

Wheel Stud Replacement
Special Tools CH 43631 Ball Joint Separator For equivalent regional tools, refer to Special Tools. Removal Procedure Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and In ...

0.0081