Chevrolet Sonic manuals

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

Special Tools

69604356 Gear Pullers

For equivalent regional tools, refer to Special Tools.


    Remove the 1st gear thrust washer (1) and the 1st gear (2)
  1. Remove the 1st gear thrust washer (1) and the 1st gear (2) using 69604356 pullersand a hydraulic press.

  2. ii
  3. Remove the following components:

  • Remove and discard the 1st/2nd gear synchronizer assembly retaining ring (1).

  • Remove the 1st/2nd gear synchronizer assembly (1) and 2nd gear assembly (2) as a unit using 69604356 pullersand a hydraulic press.


  • Separate the following components:

  • Remove the following components:

  • Remove and discard the 3rd/4th gear synchronizer assembly retaining ring (1) and the 3rd/4th gear synchronizer assembly thrust washer (2).

  • Remove the 3rd/4th gear synchronizer assembly (1) and the 4th gear assembly (2) as a unit using 69604356 pullersand a hydraulic press.


  • Separate the following components:

  • Remove the 4th gear bearing assembly (1).
  • 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 ...

    Manual Transmission Shift Lever Cable Adjustment
    Special Tools DT-527-A Adjuster or 5mm drill bit For equivalent regional tools, refer to Special Tools. Note: Not using the specified tools may lead to shift system mis-adjustment. ...

    Other materials:

    Brake Fluid
    The brake/clutch master cylinder reservoir is filled with DOT 3 brake fluid as indicated on the reservoir cap. See Engine Compartment Overview  for the location of the reservoir. There are only two reasons why the fluid level in the reservoir might go down: The fluid level goes down ...

    Sunroof Switch Replacement
    Sunroof Switch Replacement Callout Component Name Preliminary Procedure Remove the dome lamp bezel. Refer to Dome Lamp Bezel Replacement. 1 Sunroof Switch Procedure Disconnect electrical conn ...

    Engine Front Cover Gasket Installation
    Clean the sealing surfaces and remove all remains of old sealing compound material. Note: The thickness of the sealing bead should be 2 mm (0.0787 in). Apply sealing compound to the shown areas (1) and (2). Refer to  Adhesives, Fluids ...

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