Chevrolet Sonic Repair Manual: Transmission Assemble (Gen 1)
Special Tools
- 3-9506289 Universal Adapter
- R-0007758 Holding Fixture
- S-9407197 Differential Rotating Tool
- S-9407198 Differential Bearing Race Wrench
For equivalent regional tools, refer to Special Tools.
- Install the clutch and differential housing assembly (1)
onto the R-0007758 holding fixture.
- Install the front differential carrier (1).
- Install the gasket (3) and differential carrier cover (2).
- Install the front differential carrier cover bolts (1).
Tighten to 7 Y (61.96 lb in)
.
- Lubricate the O-ring seal (2) with multipurpose grease
and install onto the differential bearing adjuster (1).
- Lubricate the threads on the differential bearing adjuster
with multipurpose grease.
- Using S-9407198 differential bearing race wrench
install the front differential bearing adjuster (1).
Note:
If all the components are re-used align adjuster to marks.
If any component was replaced go to the next step.
- Align marks on the differential bearing adjuster and case (1).
Note:
If no components were replaced, the bearing adjuster can
be aligned to the marks. If any component was replaced, the following procedure
must be performed.
- Using the S-9407197 differential rotating tool
and a torque wrench, rotate the differential (1) 1 revolution per second.
- The breakaway bearing torque should be:
- Re-use bearing ?#8201;60?00 Ncm
- New Bearing ?#8201;150?10 Ncm
Using the S-9407198 bearing race wrench and the R-0007761 handle,
adjust the breakaway torque by tightening or loosing the differential bearing adjuster.
Install the differential bearing adjuster lock (2).
Apply thread locking compound and install the differential bearing adjuster
lock bolt (1). Tighten to 9 Y (79.66 lb in).
Install the back up lamp switch (1). Tighten to 20 Y
(14.75 lb ft).
Install the reverse idler gear washer (5).
Verify fork alignment before installation.
Install the case .
Install the gasket (1) and transmission case (2).
Install the transmission case bolts (3). Tighten to 15 Y
(11 lb ft).
Install the gasket (4) and transmission cover (3).
Install the long transmission cover bolts (2). Tighten to 24 Y
(18 lb ft).
Install the short transmission cover bolts (1). Tighten to 8 Y
(71 lb in).
Install the clutch release bearing (1).
Install the gasket (3) and control lever housing (2).
Install the transmission control lever housing bolts (1). Tighten to 12 Y
(106 lb in).
Install the clutch fork shaft (1).
Install the clutch fork shaft retaining bolt (2). Tighten to 35 Y
(26 lb ft).
Remove the R-0007758 holding fixture (2) and the 3-9506289 Universal
Adapter (1).
The 6T30/40/45/50 transmission utilizes a line pressure control system during
upshifts to compensate for the normal wear of transmission components. As the apply
components within the transmission ...
Special Tools
3-9506289 Universal Adapter
R-0007758 Holding Fixture
S-9407197 Differential Rotating Tool
S-9407198 Differential Bearing Race Wrench
For equivalent regional tools, refer ...
Other materials:
Rear Side Door Window Switch Bezel Replacement
Rear Side Door Window Switch Bezel Replacement
Callout
Component Name
Preliminary Procedure
Remove the rear side door trim. Refer to Rear Side Door Trim Replacement.
1
Rear Side Door Pull Handle ...
Seat Belt System Description and Operation
Restraint System
Note: If the vehicle has been in a collision, refer to Repairs
and Inspections Required After a Collision.
The vehicle has front and rear seat belts that are the primary means of occupant
restraint. Seat belts help to keep the occupants inside the passenger ...
Valve Stem Oil Seal and Valve Spring Replacement
Special Tools
207649 Rod Hairpin Clips
547324 Flange Screws
EN-840 Pliers / Remover
EN-958 Installer
EN-45059 Angle Meter
EN-50717 Kit
J-43649–2 Rods
For equivalent regional tools, refer to Special Tools.
Removal Procedure
Remove the spark plugs. Refer to Spa ...
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