Chevrolet Sonic manuals

Chevrolet Sonic Repair Manual: Differential Case Assemble

Special Tools

For equivalent regional tools, refer to Special Tools.


    Install the front differential pinion and side gear thrust washer. It must
  1. Install the front differential pinion and side gear thrust washer. It must be possible to insert the collar (1) of the thrust washer into the guide for the pinion gears in the housing.

  2. Note:

    Lubricate rotating parts on their bearing, running, seating, and pressure surfaces using transmission fluid.

  3. Install the front differential pinion gears (3) and side gears (4).
  4. Install the front differential pinion gear shaft (2) and the pinion gear shaft retaining washers (1).

  5. If both components are reused align the assembly marks (3).
  6. Install the front differential ring gear (2).
  7. Warning:

    Refer to Safety Glasses Warning.

  8. Install the front differential ring gear bolts (1). Tighten to 90 N•m (66.4 lb ft)

    .



  9. Install the ring front wheel speed sensor reluctor wheel (1) using the S-9407194 installer and a hydraulic press.


  10. Install the front differential bearing assemblies (1) using the S-9407195 installer and a hydraulic press.


  11. Install the front wheel drive shaft oil seal (3) using the R-0007761 handle  (1), S-9707500 seal installer  (2), and the J-810721 support base  (4).


  12. Install the front differential bearing race (3) using the R-0007761 handle  (1) and the R-0407012 driver  (2).
Differentials
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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 ...

Other materials:

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 Remover R-0007761 Universal Handle for Pullers and Installers S-9407195 Pinion Gear Case Bearing ...

Engine Replacement (Automatic Transmission)
Special Tools J-45859 Wheel Drive Shaft Remover CH-807 Closure Plugs For equivalent regional tools, refer to Special Tools. Removal Procedure Remove the battery and battery tray. Refer to Battery Tray Replacement. Relieve the fuel system pressure. Refer to Fuel Pre ...

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 ...

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