Chevrolet Sonic Repair Manual: 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 Remover
• R-0007761 Universal Handle for Pullers and Installers
• S-9407195 Pinion Gear Case Bearing Installer
• T-9804678 Speed Sensor Reluctor Wheel Remover

For equivalent regional tools, refer to Special Tools.

1. Remove the front wheel drive shaft oil seal (1) from the front differential bearing adjuster (2).



Note:

Do not interchange outer and inner races respectively when re-using tapered roller bearings.

2. Remove the front differential bearing race (1) from the front differential bearing adjuster using the R-0007761 handle  (2), R-0407011 remover  (3), and the J-810721 support base  (4).



3. Remove the ring front wheel speed sensor reluctor wheel (1) using the 6-9607346 puller  (2), S-9407195 installer  (3), and the T-9804678 remover  (4).



4. Remove the front differential bearing assemblies (3) using the J-810704 puller  (1) and R-0006749 support base  (2) .



5. Place a mark (3) on the differential and the differential ring gear for realigning parts during assembly in case both components are reused.
6. Remove the front differential ring gear bolts (1) and the front differential ring gear (2).


7. Remove the pinion gear shaft retaining washers (1) and the front differential pinion gear shaft (2).
8. Remove the front differential pinion gears (3) and side gears (4).
9. Remove the front differential pinion and side gear thrust washer (5).

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