Chevrolet Sonic Repair Manual: Differential Case Assemble

Chevrolet Sonic Repair Manual / Powertrain / Driveline / Differentials / Differential Case Assemble

Special Tools

J-810721 Axle Shaft Seal Remover Support Base
R-0407011 Bearing Race Remover
R-0407012 Differential Carrier Cone Bearing Cap Driver
R-0007761 Universal Handle for Pullers and Installers
S-9407194 Speed Sensor Impeller Ring Installer
S-9407195 Pinion Gear Case Bearing Installer
S-9707500 Seal Installer

For equivalent regional tools, refer to Special Tools.

Install the front differential pinion and side gear thrust washer. It must

Install the front differential pinion and side gear thrust washer. It must be possible to insert the collar (1) of the thrust washer into the guide for the pinion gears in the housing.

Note:

Lubricate rotating parts on their bearing, running, seating, and pressure surfaces using transmission fluid.

Install the front differential pinion gears (3) and side gears (4).
Install the front differential pinion gear shaft (2) and the pinion gear shaft retaining washers (1).

If both components are reused align the assembly marks (3).
Install the front differential ring gear (2).

Warning:

Refer to Safety Glasses Warning.

Install the front differential ring gear bolts (1). Tighten to 90 N•m (66.4 lb ft)
.

Install the ring front wheel speed sensor reluctor wheel (1) using the S-9407194 installer and a hydraulic press.

Install the front differential bearing assemblies (1) using the S-9407195 installer and a hydraulic press.

Install the front wheel drive shaft oil seal (3) using the R-0007761 handle (1), S-9707500 seal installer (2), and the J-810721 support base (4).

Install the front differential bearing race (3) using the R-0007761 handle (1) and the R-0407012 driver (2).

Differential Case Disassemble

Special Tools 6-9607346 Sensor Ring Gear Puller J-810704 Steering Column Center Bar Puller J-810721 Axle Shaft Seal Remover Support Base R-0006749 Support Base R-0407011 Bearing Race Rem ...

Other materials:

Windshield Wiper/Washer
Sedan Hatchback The windshield wiper/washer lever is on the right side of the steering column. Move the lever to one of the following positions: HI: Use for fast wipes. LO: Use for slow wipes. Hatchback Shown, Sedan Similar INT: (Intermittent Wipes): Move the lever up to INT for intermi ...

Turn Signal Switch Bracket Replacement
Turn Signal Switch Bracket Replacement Callout Component Name Preliminary Procedure Remove the inflatable restraint steering wheel module coil. Refer to Steering Wheel Airbag Coil Replacement. 1 ...

Rear Compartment Lid Hinge Torque Rod Replacement
Rear Compartment Lid Hinge Torque Rod Replacement Callout Component Name Warning: Refer to Hood Hold-Open Device Warning. Preliminary Procedure Open and support the rear compartment lid. Special Tools BO-125 ...

0.006