Chevrolet Sonic Repair Manual: Main Shaft Assemble (Gen 1)
Special Tools
3-0207944 Main Shaft Tapered Bearing Insert Tool
For equivalent regional tools, refer to Special Tools.
- Install the 4th gear bearing assembly (1).
Note:
The 3rd gear blocking ring lugs must be aligned with the
3rd/4th gear synchronizer assembly grooves.
Note:
The groove on the 3rd/4th gear synchronizer assembly (2)
should point toward the 4th gear assembly.
- Assemble the following components:
- 3rd/4th gear synchronizer assembly (1)
- 3rd gear blocking ring (3)
- 4th gear assembly (4)
Install the 3rd/4th gear synchronizer assembly (2) and the
4th gear assembly (1) as a unit using 3-0207944 bearing insert tool (3)
and a hydraulic press.
Install the 3rd/4th gear synchronizer assembly thrust washer (2)
and the NEW 3rd/4th gear synchronizer assembly retaining ring (1).
Install the following components:
- 3rd gear blocking ring (6)
- 3rd gear bearing assembly (5)
- 3rd gear assembly (4)
- 3rd gear thrust washer (3)
- 3rd gear thrust washer retaining ring (2)
- 2nd gear bearing assembly (1)
Note:
The lugs on the blocking rings must be aligned with the 2nd
gear assembly and the 1st/2nd gear synchronizer assembly.
Assemble the following components:
- 1st/2nd gear synchronizer assembly (1)
- 1st/2nd gear outer blocking ring (2)
- 1st/2nd gear intermediate cone ring (3)
- 1st/2nd gear inner blocking ring (4)
- 2nd gear assembly (5)
Install the 1st/2nd gear synchronizer assembly (2) and the
2nd gear assembly (1) as a unit using 3-0207944 bearing insert tool (3)
and a hydraulic press.
Install the NEW 1st/2nd gear synchronizer assembly retaining
ring (1).
Note:
The lugs on the blocking rings must be aligned with the 1st/2nd
gear synchronizer assembly grooves.
Install the following components:
- 1st/2nd gear outer blocking ring (5)
- 1st/2nd gear intermediate cone ring (4)
- 1st/2nd gear inner blocking ring (3)
- 1st gear bearing assembly (2)
- 1st gear (1)
Install the 1st gear thrust washer (1) and the thrust washer (2) in the 1st/2nd
gear synchronizer assembly using a suitable tube (3) and a hydraulic press.
Note: The input shaft rear bearing retaining ring (2) remains
loose on the shaft.
Remove the input shaft rear bearing assembly (1) using
a hydraulic press.
Rem ...
Special Tools
3-0207944 Main Shaft Tapered Bearing Insert Tool
For equivalent regional tools, refer to Special Tools.
Install the 4th gear bearing assembly (1).
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Other materials:
Special Tools
Illustration
Tool Number/ Description
BO-24402-A
J-24402-A
Glass Sealant Cold Knife Remover
equalizermagnum
BO-39032
J-39032
Stationary Glass Removal Tool
...
Lubrication Description
Oil is applied under pressure to the crankshaft (8), connecting rods (5), camshaft
adjuster (1), camshaft bearing surfaces (3) and valve tappets (4). All other moving
parts are lubricated by gravity flow or splash. Oil enters the rotor type oil pump (10)
...
Engine Replacement (Manual 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
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