Chevrolet Sonic Repair Manual: Gears Cleaning and Inspection (Gen 2)
- Gears
-
- Clean the following gears in a suitable solvent and air dry all the parts.
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.
- 1st Gear (1)
- 2nd Gear Assembly (4)
- 3rd Gear Assembly (3)
- 4th Gear Assembly (2)
- 5th Gear Assembly - Driven (5)
- 5th Gear - Driving (6)
- 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 Gears and Shaft
-
- Clean the reverse spur gear (1), reverse helical gear (2), and shaft (5) in a suitable solvent and air dry all the parts.
- Inspect the reverse spur gear bushings (4) and reverse helical gear bushings (3) for the following conditions:
- Excessive wear
- Scoring
- Pitting
- Replace the reverse gears if the bushings are faulty.
- Inspect the reverse gear shaft for the following conditions:
- Excessive wear
- Scoring
- Pitting
- Replace the reverse gear shaft if it is faulty.
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 exp ...
Input Shaft Assemble
Special Tools
J-840733 Driver
For equivalent regional tools, refer to Special Tools.
Note: Ensure the input shaft rear bearing retaining ring (2) is
placed on the input s ...
Other materials:
Speaker Replacement Reference
Speaker Replacement Reference
Component
Repair Instruction
Front Door Speaker
Radio Front Side Door Speaker Replacement
Front Tweeter Speaker
Radio Windshield Side Garnish Molding Speaker
...
Brake Caliper Inspection
Warning: Refer to Brake Dust Warning.
Inspect the brake caliper housing (1) for cracks, excess wear, and/or damage.
If any of these conditions are present, the brake caliper requires replacement.
Inspect the caliper piston dust boot seal (2) for cracks, tears, ...
Front Brake Caliper Replacement
Removal Procedure
Warning: Refer to Brake Dust Warning.
Warning: Refer to Brake Fluid Irritant Warning.
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 Install ...
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