Chevrolet Sonic Repair Manual: Main Shaft Assemble (Gen 2)

Chevrolet Sonic Repair Manual / Powertrain / Transmission/Transaxle / Manual / General / Main Shaft Assemble (Gen 2)

Special Tools

3-0207944 Main Shaft Tapered Bearing Insert Tool

For equivalent regional tools, refer to Special Tools.

Install the 4th gear bearing assembly (1).

Install the 4th gear bearing assembly (1).

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Note:

The 3rd gear blocking ring lugs must be aligned with the 3rd/4th gear synchronizer assembly grooves.

Note:

The groove on the 3rd/4th gear synchronizer assembly (2) should point toward the 4th gear assembly.

Assemble the following components:

3rd/4th gear synchronizer assembly (1)
4th gear outer blocking ring (3)
4th gear intermediate blocking ring (4)
4th gear inner blocking ring (5)
4th gear assembly (6)

Install the 3rd/4th gear synchronizer assembly (2) and the 4th gear assembly (1) as a unit using 3-0207944 bearing insert tool (3) and a hydraulic press.

Install the 3rd/4th gear synchronizer assembly thrust washer (2) and the NEW 3rd/4th gear synchronizer assembly retaining ring (1).

Install the following components:

3rd gear outer blocking ring (8)
3rd gear intermediate blocking ring (7)
3rd gear inner blocking ring (6)
3rd gear bearing assembly (5)
3rd gear assembly (4)
3rd gear thrust washer (3)
3rd gear thrust washer retaining ring (2)
2nd gear bearing assembly (1)

Note:

The lugs on the blocking rings must be aligned with the 2nd gear assembly and the 1st/2nd gear synchronizer assembly.

Assemble the following components:

1st/2nd gear synchronizer assembly (1)
1st/2nd gear outer blocking ring (2)
1st/2nd gear intermediate cone ring (3)
1st/2nd gear inner blocking ring (4)
2nd gear assembly (5)

Install the 1st/2nd gear synchronizer assembly (2) and the 2nd gear assembly (1) as a unit using 3-0207944 bearing insert tool (3) and a hydraulic press.

Install the NEW 1st/2nd gear synchronizer assembly retaining ring (1).

Note:

The lugs on the blocking rings must be aligned with the 1st/2nd gear synchronizer assembly grooves.

Install the following components:

1st/2nd gear outer blocking ring (5)
1st/2nd gear intermediate cone ring (4)
1st/2nd gear inner blocking ring (3)
1st gear bearing assembly (2)
1st gear (1)

Install the 1st gear thrust washer (1) and the thrust washer (2) in the 1st/2nd gear synchronizer assembly using a suitable tube (3) and a hydraulic press.

Main Shaft Assemble (Gen 1)

Special Tools 3-0207944 Main Shaft Tapered Bearing Insert Tool For equivalent regional tools, refer to Special Tools. Install the 4th gear bearing assembly (1). Note: T ...

Main Shaft Disassemble (Gen 1)

Table 1: 1st Gear Removal Table 2: 1st Gear Blocking Rings Removal Table 3: 1st and 2nd Gear Synchronizer Hub Retaining Ring Removal Table 4: 1st ...

Other materials:

Windshield Wiper/Washer
Sedan Hatchback The windshield wiper/washer lever is on the right side of the steering column. Move the lever to one of the following positions: HI: Use for fast wipes. LO: Use for slow wipes. Hatchback Shown, Sedan Similar INT: (Intermittent Wipes): Move the lever up to INT for intermi ...

Brake Pedal Position Sensor Calibration
Calibration Criteria Note: Do not apply the brake pedal during the brake pedal position sensor calibration procedure. Any movement of the brake pedal during this procedure will cause the calibration procedure to fail. If this occurs, the brake pedal position sensor calibrati ...

Battery Replacement
Removal Procedure Open the hood. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection. Remove the battery retainer bolt (1) and the battery retainer (2). Loosen the battery positive cable ju ...

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