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:
Heater Outlet Hose Replacement (LUV)
Heater Outlet Hose Replacement
Callout
Component Name
Preliminary Procedures
Drain the engine coolant. Refer to Cooling System Draining and Filling.
Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacemen ...
Inspection/Maintenance System Check
Diagnostic Instructions
Perform the Diagnostic System Check - Vehicle
prior to using this diagnostic procedure.
Review Diagnostic System Check - Vehicle
for an overview of the diagnostic approach.
Diagnostic Procedure Instructions provides
an overview of each diagn ...
Heated Oxygen Sensor Replacement - Sensor 2
Heated Oxygen Sensor Replacement - Sensor 2
Callout
Component Name
1
Heated Oxygen Sensor 2
Warning: In order to avoid being burned, do not service the
exhaust system while it is still hot. Service the ...
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