Chevrolet Sonic Repair Manual: Main Shaft Assemble (Gen 1)

Chevrolet Sonic Repair Manual / Powertrain / Transmission/Transaxle / Manual / General / 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).

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.

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:

Personalization Menu (Radio with Touchscreen)
Settings can be made with the ignition ON and the vehicle not moving. Use the audio system controls to access the personalization menus for customizing vehicle features. The following are all possible personalization features. Depending on the vehicle, some may not be available. (Home): Pres ...

Front Wheel Drive Shaft Inner Joint and Boot Replacement
Special Tools DT-35910 Drive Axle Boot Clamp Pliers For equivalent regional tools, refer to Special Tools. Disassemble Procedure Note: There are types of inner joints available. If the inner joint is connected with the CV style joint, the inner joint is not serviced separa ...

Main Shaft Disassemble (Gen 1)
Table 1: 1st Gear Removal Table 2: 1st Gear Blocking Rings Removal Table 3: 1st and 2nd Gear Synchronizer Hub Retaining Ring Removal Table 4: 1st and 2nd Gear Synchronizer Hub and 2nd Gear Removal Table 5: 2nd Gear Bearing Remova ...

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