Chevrolet Sonic Repair Manual: Clutch and Differential Housing Cleaning and Inspection

Chevrolet Sonic Repair Manual / Powertrain / Transmission/Transaxle / Manual / General / 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 the clutch housing for the following conditions:

Cracks
Replace the clutch housing if cracks are found.
Scratches
Burrs
Nicked mounting surfaces
Damaged sealing surfaces
Damaged front or rear bearing bores
Damaged alignment pins

Inspect the machined mating surfaces for flatness. Check the mating surfaces with a straight edge.

Inspect the bearing bores for wear, scratches or grooves.

Inspect the bushings for excessive wear. Replace worn bushings.

Use a fine mill file to dress minor scratches or burrs.

If scratches, or grooves or scoring cannot be removed by hand with a soft stone or crocus cloth, replace the component.

Clutch and Differential Housing Assemble

Special Tools R-0007761 Universal Handle for Pullers and Installers R-0407009 Countershaft Front Bearing Driver R-0407010 Input Shaft Needle Bearing Puller and Driver R-0407014 Gearshift De ...

Clutch and Differential Housing Disassemble

Special Tools M-680770 Universal Sliding Mallet R-0007758 Holding Fixture R-0407008 Counter Shaft Bearing Remover R-0407010 Input Shaft Needle Bearing Puller and Driver R-0407013 Gearshi ...

Other materials:

Forward Collision Alert (FCA) System
For vehicles with this feature, read the following section before using it. The Forward Collision Alert (FCA) system may help to avoid or reduce the harm caused by front-end crashes. FCA provides a flashing red visual alert and beeps when approaching a vehicle directly ahead too quickly. FCA al ...

Cleaning Exterior Lamps/ Lenses, Emblems, Decals and Stripes
Use only lukewarm or cold water, a soft cloth, and a car washing soap to clean exterior lamps, lenses and emblems. Follow instructions under "Washing the Vehicle" previously in this section. Lamp covers are made of plastic, and some have a UV protective coating. Use only lukewarm wat ...

Crankshaft and Bearing Removal
Identify all the connecting rod bearing caps (1). Remove the 4 bolts. Remove the connecting rod bearing caps 1 and 4 (1). Turn the crankshaft through 180°. Remove the 4 bolts. Remove the connecting rod bearing caps 2 and 3 ( ...

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