Chevrolet Sonic manuals

Chevrolet Sonic Repair Manual: Clutch and Differential Housing Assemble

Chevrolet Sonic Repair Manual / Powertrain / Driveline / Differentials / Clutch and Differential Housing Assemble

Special Tools

For equivalent regional tools, refer to Special Tools.


    Install the shift shaft bushings (3) using the R-0407014 bushing
  1. Install the shift shaft bushings (3) using the R-0407014 bushing driver  (2) and R-0007761 handle  (1).


  2. Install the main shaft front bearing assembly (3) using the R-0407009 driver  (2) and the R-0007761 handle  (1).


  3. Install the input shaft front bearing assembly (3) using the R-0407010 driver  (2) and the R-0007761 handle  (1).


  4. Note:

    Align the tabs on the clutch yoke shaft bushings to the slots in the clutch and differential housing.

  5. Install the clutch yoke shaft bushings (1).

  6. Install the clutch release bearing collar seal (3).
  7. Install the clutch release bearing collar (2).
  8. Caution:

    Refer to Fastener Caution.

  9. Install the clutch release bearing collar bolt (1) and tighten to 5 Y (44.3 lb in)

    .



  10. Install the front wheel drive shaft oil seal assembly (3) using the S-9707500 seal installer  (2) and the R-0007761 handle  (1).


  11. Install the transmission magnet (1). Tighten to 4 Y (35.4 lb in) plus 45° plus an additional 90°

    .



  12. Install the NEW vehicle speed sensor O-ring seal (3).
  13. Install the vehicle speed sensor assembly (2).
  14. Install the vehicle speed sensor bolt (1). Tighten to 5 Y (44 lb in)

    .

Differential Case Disassemble
Special Tools 6-9607346 Sensor Ring Gear Puller J-810704 Steering Column Center Bar Puller J-810721 Axle Shaft Seal Remover Support Base R-0006749 Support Base R-0407011 Bearing Race Rem ...

Clutch and Differential Housing Cleaning and Inspection
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. ...

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 ...

Rear Side Door Weatherstrip Replacement - Body Side
Rear Side Door Weatherstrip Replacement - Body Side Callout Component Name Preliminary Procedures Remove the upper center pillar trim. Refer to Center Pillar Upper Trim Panel Replacement. Remove the lower center pillar tr ...

Instrument Panel Lower Intermediate Reinforcement Replacement
Instrument Panel Lower Intermediate Reinforcement Replacement Callout Component Name Preliminary Procedures Disable the SIR system. Refer to SIR Disabling and Enabling. Remove the passenger inflatable restraint instrument ...

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