Chevrolet Sonic Repair Manual: Gears Cleaning and Inspection (Gen 1)

Gears

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.

1. Clean the following gears in a suitable solvent and air dry all the parts.

• 1st gear (1)
• 2nd gear assembly (4)
• 3rd gear assembly (3)
• 4th gear assembly (2)
• Reverse idler gear (5)

Inspect the gear tooth surfaces on all the gears for the following conditions:

• Cracks
• Pitting
• Nicks
• Chipped gear teeth
• High spots ?small shiny spots on the gear teeth mating surfaces

Input Shaft

1. Clean the input shaft (1) in a suitable solvent.
2. Clean and air dry the oil gallery.
3. Inspect the input shaft bearing surfaces for the following conditions:

• Wear
• Lack of lubricant
• Debris embedded in the oil grooves
• Brinelling

Inspect the input shaft splines for wear or damage.

Replace the input shaft if any of the above conditions are found.

Main Shaft

1. Clean the main shaft (1) in a suitable solvent.
2. Clean and air dry the oil gallery.
3. Inspect the main shaft bearing surfaces for the following conditions:

• Wear
• Lack of lubricant
• Debris embedded in the oil grooves
• Brinelling

Inspect the main shaft splines for wear or damage.

Replace the main shaft if any of the above conditions are found.

Reverse Idler Gear and Shaft

1. Clean the reverse idler gear (1) and shaft (2) in a suitable solvent and air dry all the parts.
2. Inspect the reverse idler gear bushing (3) for the following conditions:

• Excessive wear
• Scoring
• Pitting

Replace the reverse idler gear if the bushing is faulty.

Inspect the reverse idler gear shaft for the following conditions:

• Excessive wear
• Scoring
• Pitting

Replace the reverse idler gear shaft if it is faulty.