Chevrolet Sonic Repair Manual: Gears Cleaning and Inspection (Gen 2)
- 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.
- 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)
- 5th Gear Assembly - Driven (5)
- 5th Gear - Driving (6)
- 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
-
- Clean the input shaft (1) in a suitable solvent.
- Clean and air dry the oil gallery.
- 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
-
- Clean the main shaft (1) in a suitable solvent.
- Clean and air dry the oil gallery.
- 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 Gears and Shaft
-
- Clean the reverse spur gear (1), reverse helical gear (2),
and shaft (5) in a suitable solvent and air dry all the parts.
- Inspect the reverse spur gear bushings (4) and reverse
helical gear bushings (3) for the following conditions:
- Excessive wear
- Scoring
- Pitting
- Replace the reverse gears if the bushings are faulty.
- Inspect the reverse gear shaft for the following conditions:
- Excessive wear
- Scoring
- Pitting
- Replace the reverse gear shaft if it is faulty.
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 exp ...
Special Tools
J-840733 Driver
For equivalent regional tools, refer to Special Tools.
Note: Ensure the input shaft rear bearing retaining ring (2) is
placed on the input s ...
Other materials:
Inside Rearview Mirror Replacement
Inside Rearview Mirror Replacement
Callout
Component Name
1
Inside Rearview Mirror Cover
Procedure
Remove the wire harness cover, sliding the cover upward releasing
the cover from the support.
Disconnect ...
Headlining Trim Panel Replacement (Sedan with Sunroof)
Headlining Trim Panel Replacement
Callout
Component Name
Warning: Do not attempt to repair or alter the head impact
energy-absorbing material glued to the headliner or to the garnish trims.
If the material is damaged ...
Transmission Identification Information
456789
(1)
Code for Automatic Transmission
(2)
Model Year
(3)
Model for Transmission
(4)
Transmission Family
(5)
Source Code for Plant
(6)
Calender Year
(7)
Julian Date
( ...
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