Chevrolet Sonic Repair Manual: Differential Case Assemble

Chevrolet Sonic Repair Manual / Powertrain / Transmission/Transaxle / Manual / General / Differential Case Assemble

Special Tools

J-810721 Axle Shaft Seal Remover Support Base
R-0407011 Bearing Race Remover
R-0407012 Differential Carrier Cone Bearing Cap Driver
R-0007761 Universal Handle for Pullers and Installers
S-9407194 Speed Sensor Impeller Ring Installer
S-9407195 Pinion Gear Case Bearing Installer
S-9707500 Seal Installer

For equivalent regional tools, refer to Special Tools.

Install the front differential pinion and side gear thrust

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.

Note:

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

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

If both components are reused align the assembly marks (3).
Install the front differential ring gear (2).

Warning:

Refer to Safety Glasses Warning.

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

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

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

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).

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

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 ...

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:

How to Inspect the Engine Air Cleaner/Filter
To inspect the engine air cleaner/ filter, remove the filter from the vehicle and lightly shake the filter to release loose dust and dirt. If the filter remains covered with dirt, a new filter is required. To inspect or replace the air cleaner/ filter: 1.4L L4 Engine 1.8L L4 Engine 1. Re ...

Taillamps, Turn Signal, Stoplamps, and Back-Up Lamps
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Brake Drum Diameter Measurement
Warning: Refer to Brake Dust Warning. Remove brake drum. Refer to Brake Drum Replacement Clean the brake shoe lining contact surface of the brake drum (2) with denatured alcohol or an equivalent approved brake cleaner. Using a brake drum micrometer (1) calibra ...

0.008