Chevrolet Sonic manuals

Chevrolet Sonic Repair Manual: Gears Cleaning and Inspection (Gen 1)

Chevrolet Sonic Repair Manual / Powertrain / Transmission/Transaxle / Manual / General / Gears Cleaning and Inspection (Gen 1)

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 exposed to chemicals.

  1. Clean the following gears in a suitable solvent and air dry all the parts.
  • 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.
    1. Clean the input shaft (1) in a suitable solvent.
    2. Clean and air dry the oil gallery.
    3. 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.
    1. Clean the main shaft (1) in a suitable solvent.
    2. Clean and air dry the oil gallery.
    3. 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
    1. Clean the reverse idler gear (1) and shaft (2) in a suitable solvent and air dry all the parts.
    2. 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:

    Engine Oil Cooler Inlet Pipe Replacement (LUW)
    Removal Procedure Drain the cooling system. Refer to Cooling System Draining and Filling. Remove the exhaust manifold with catalytic converter. Refer to Exhaust Manifold with Catalytic Converter Replacement. Remove the engine oil cooler pipe bolts (1) an ...

    Transmission Disassemble (Gen 2)
    Special Tools 3-9506289 Universal Adapter R-0007758 Holding Fixture S-9407198 Differential Bearing Race Wrench For equivalent regional tools, refer to Special Tools. Attach R-0007758 holding fixture (2) to the transmission. Attach R-0007758 holding fixture (2 ...

    General information
    Park the vehicle as far as possible from moving traffic in the event of a breakdown. In the event of a flat tire, park the vehicle on a level surface. If you are on a steep hill, be especially careful. Set the parking brake. Switch the emergency flashers on. Have the passengers exit the vehi ...

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