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:

Communication Interface Module Replacement
Communication Interface Module Replacement Callout Component Name Preliminary Procedure Remove the instrument panel lower compartment. Refer to Instrument Panel Lower Compartment Replacement. Remove the instrument pa ...

Brake Pad Inspection
Warning: Refer to Brake Dust Warning. Inspect the disc brake pads at regular intervals, or whenever the tire and wheel assemblies are removed from the vehicle. If replacement is necessary, always replace disc brake pads in axle sets. Inspect both edges of the disc brake ...

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. Clean the clutch housing (1) with a suitable solvent. Air dry all the parts. Inspect ...

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