Chevrolet Sonic manuals

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).
  1. Install the 4th gear bearing assembly (1).

  2. 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.

  3. Assemble the following components:

  • 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:

  • 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:

  • 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:

  • 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.
  • Input Shaft Disassemble
    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 ...

    Main Shaft Assemble (Gen 2)
    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). in!i.l.i-if ...

    Other materials:

    Radio Controls without Touchscreen
    The buttons used to control the radio are: P /VOL: Press to turn the radio on and off. RADIO/BAND: Press to choose between AM, FM, and SiriusXM®, if equipped. Push/MENU/TUNE Knob: Turn to navigate the available menus. Turn to search for stations. INFO: Press to display additional information ...

    Brake Warning System Description and Operation
    Brake Warning Indicator Brake Warning Block Diagram B80Park Brake SwitchB20Brake Fluid Level SwitchK9Body Control ModuleP16Instrument Cluster Hard-Wired Serial D ...

    Drum Brake Adjusting Hardware Inspection
    Warning: Refer to Brake Dust Warning. Visually inspect the adjuster actuator spring (1) for the following conditions: Excessive stretching Excessive bending Excessive corrosion Broken Missing If any of the conditions listed were found, the adjuster actu ...

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