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:
Body Lock Pillar Upper Trim Panel Replacement (Sedan)
Body Lock Pillar Upper Trim Panel Replacement
Callout
Component Name
Preliminary Procedure
Disable the SIR system. Refer to SIR Disabling and Enabling.
Remove the body side trim panel. Refer to Body Side Trim Panel Replace ...
Front Wheel Drive Shaft Inner Joint and Boot Replacement
Special Tools
DT-35910 Drive Axle Boot Clamp Pliers
For equivalent regional tools, refer to Special Tools.
Disassemble Procedure
Note: There are types of inner joints available. If the inner
joint is connected with the CV style joint, the inner joint is not serviced
separa ...
Low and Reverse and 1-2-3-4 Clutch Housing, and 1-2-3-4 Clutch Plate Installation
(6T40/45/50)
Low and Reverse and 1-2-3-4 Clutch Housing, and 1-2-3-4 Clutch Plate
Installation
Callout
Component Name
1
Low and Reverse and 1??? Clutch Housing
Note: The longer legs face the bottom of the case and the
...
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