Chevrolet Sonic Repair Manual: Differential Case Assemble

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

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? (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).

Clutch and Differential Housing Disassemble

Special Tools M-680770 Universal Sliding Mallet R-0007758 Holding Fixture R-0407008 Counter Shaft Bearing Remover R-0407010 Input Shaft Needle Bearing Puller and Driver R-0407013 Gearshi ...

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:

Towing the Vehicle
Caution Incorrectly towing a disabled vehicle may cause damage. The damage would not be covered by the vehicle warranty. Do not lash or hook to the chassis components — including the front and rear subframes, suspension control arms, and links — during towing and recovery of a disabled ve ...

Front Side Door Adjustment
Front Side Door Adjustment Callout Component Name Preliminary Procedure Remove the front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement. 1 Front Side Door Caution: Refer to ...

Engine Front Cover and Oil Pump Cleaning and Inspection
Engine Front Cover Cleaning Procedure Clean the engine front cover sealing surface. Warning: Wear safety glasses when using compressed air in order to prevent eye injury. Caution: To ensure proper engine lubrication, clean clogged or contaminated oil g ...

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