Chevrolet Sonic Repair Manual: Gears Cleaning and Inspection (Gen 1)
- Gears
-
- Clean the following gears in a suitable solvent and air dry all the parts.
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.
- 1st gear (1)
- 2nd gear assembly (4)
- 3rd gear assembly (3)
- 4th gear assembly (2)
- Reverse idler gear (5)
- Inspect the gear tooth surfaces on all the gears for the following conditions:
- Cracks
- Pitting
- Nicks
- Chipped gear teeth
- High spots ?small shiny spots on the gear teeth mating surfaces
- Input Shaft
-
- Clean the input shaft (1) in a suitable solvent.
- Clean and air dry the oil gallery.
- Inspect the input shaft bearing surfaces for the following conditions:
- Wear
- Lack of lubricant
- Debris embedded in the oil grooves
- Brinelling
- Inspect the input shaft splines for wear or damage.
- Replace the input shaft if any of the above conditions are found.
- Main Shaft
-
- Clean the main shaft (1) in a suitable solvent.
- Clean and air dry the oil gallery.
- Inspect the main shaft bearing surfaces for the following conditions:
- Wear
- Lack of lubricant
- Debris embedded in the oil grooves
- Brinelling
- Inspect the main shaft splines for wear or damage.
- Replace the main shaft if any of the above conditions are found.
- Reverse Idler Gear and Shaft
-
- Clean the reverse idler gear (1) and shaft (2) in a suitable solvent and air dry all the parts.
- Inspect the reverse idler gear bushing (3) for the following conditions:
- Excessive wear
- Scoring
- Pitting
- Replace the reverse idler gear if the bushing is faulty.
- Inspect the reverse idler gear shaft for the following conditions:
- Excessive wear
- Scoring
- Pitting
- Replace the reverse idler gear shaft if it is faulty.
Gear Position Sensor Replacement
Gear Position Sensor Replacement
Callout
Component Name
Preliminary Procedure
Unclip the engine control module (ECM) and bracke ...
Gears Cleaning and Inspection (Gen 2)
Gears
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 exp ...
Other materials:
Instrument Panel Lower Compartment Replacement
Instrument Panel Lower Compartment Replacement
Callout
Component Name
Preliminary Procedure
Open the instrument panel lower compartment to the full open position.
Disconnect the instrument panel compartment dampener from t ...
Roof Outer Panel Replacement (4NB)
Removal Procedure
Warning: Refer to Approved Equipment for Collision Repair
Warning.
Disable the SIR system. Refer to SIR Disabling and Enabling.
Disconnect the negative battery cable. Refer to Battery Negative Cable
Disconnection and Connection.
Remove all ...
Cleanliness and Care
An automobile engine is a combination of many machined, honed, polished, and
lapped surfaces with tolerances that are measured in ten thousandths of an inch.
When any internal engine parts are serviced, care and cleanliness are important.
A liberal coating of engine oil should be applied to fr ...
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