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

Chevrolet Sonic Repair Manual / Powertrain / Transmission/Transaxle / Manual / Transmission Assembly / Shift Fork Cleaning and Inspection (Gen 1)

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 components with a suitable solvent. Air dry all the parts.

3rd and 4th shift fork assembly (1)
5th shift blocking guide (2)
3rd and 4th shift shaft (3)
1st and 2nd shift fork assembly (4)
1st and 2nd shift shaft (5)
5th shift fork assembly (6)
Reverse shift shaft (7)
Reverse shift fork assembly (8)

Inspect the following components for excessive wear, fractures or distortion.

3rd and 4th shift fork assembly (1)
5th shift blocking guide (2)
1st and 2nd shift fork assembly (3)
5th shift fork assembly (4)
Reverse shift fork assembly (5)

Inspect the shift shaft lever bushings for excessive wear.

Inspect the shift fork nylon inserts (1) for wear.

Replace parts that are fractured, excessively worn, or distorted.

Replace an excessively worn or burred shift shaft.

Transmission Assembly

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Shift Fork Cleaning and Inspection (Gen 2)

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. ...

Other materials:

Vehicle Alarm System
This vehicle has an anti-theft alarm system. The indicator light on the instrument panel near the windshield indicates the status of the system. Off: Vehicle is disarmed. On Solid: Vehicle is secured during the delay to arm the system. Fast Flash: Vehicle is unsecured. A door, the hood, or t ...

Seat Adjustment
Manual Seats Warning You can lose control of the vehicle if you try to adjust a driver seat while the vehicle is moving. Adjust the driver seat only when the vehicle is not moving. To adjust a manual seat: 1. Pull the handle at the front of the seat. 2. Slide the seat to the desired positio ...

Fuel Tank Replacement
Removal Procedure Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection. Relieve the fuel pressure. Refer to Fuel Pressure Relief. Drain the fuel Tank. Refer to Fuel Tank Draining. Lift and support the vehicle. Refer ...

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