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:
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 ...
Heater Inlet Hose Replacement (LDE, LUW)
Special Tools
BO-38185 Hose Clamp Pliers
For equivalent regional tools, refer to Special Tools.
Removal Procedure
Drain the cooling system. Refer to Cooling System Draining and Filling.
Disengage the heater inlet hose quick connect clip (1) at the heater
...
Manual Transmission Shift Lever Cable Adjustment
Special Tools
DT-527-A Adjuster or 5mm drill bit
For equivalent regional tools, refer to Special Tools.
Note: Not using the specified tools may lead to shift system mis-adjustment.
Remove the floor console. Refer to
Front Floor Console Replacement.
Lift upward an ...
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