Chevrolet Sonic manuals

Chevrolet Sonic Repair Manual: Main Shaft Assemble (Gen 1)

Special Tools

3-0207944 Main Shaft Tapered Bearing Insert Tool

For equivalent regional tools, refer to Special Tools.


    Install the 4th gear bearing assembly (1).
  1. Install the 4th gear bearing assembly (1).

  2. Note:

    The 3rd gear blocking ring lugs must be aligned with the 3rd/4th gear synchronizer assembly grooves.

    Note:

    The groove on the 3rd/4th gear synchronizer assembly (2) should point toward the 4th gear assembly.

  3. Assemble the following components:

  • Install the 3rd/4th gear synchronizer assembly (2) and the 4th gear assembly (1) as a unit using 3-0207944 bearing insert tool  (3) and a hydraulic press.


  • Install the 3rd/4th gear synchronizer assembly thrust washer (2) and the NEW 3rd/4th gear synchronizer assembly retaining ring (1).

  • Install the following components:

  • Note:

    The lugs on the blocking rings must be aligned with the 2nd gear assembly and the 1st/2nd gear synchronizer assembly.

  • Assemble the following components:

  • Install the 1st/2nd gear synchronizer assembly (2) and the 2nd gear assembly (1) as a unit using 3-0207944 bearing insert tool  (3) and a hydraulic press.


  • Install the NEW 1st/2nd gear synchronizer assembly retaining ring (1).

  • Note:

    The lugs on the blocking rings must be aligned with the 1st/2nd gear synchronizer assembly grooves.

  • Install the following components:

  • Install the 1st gear thrust washer (1) and the thrust washer (2) in the 1st/2nd gear synchronizer assembly using a suitable tube (3) and a hydraulic press.
  • Input Shaft Disassemble
    Note: The input shaft rear bearing retaining ring (2) remains loose on the shaft. Remove the input shaft rear bearing assembly (1) using a hydraulic press. Rem ...

    Main Shaft Assemble (Gen 2)
    Special Tools 3-0207944 Main Shaft Tapered Bearing Insert Tool For equivalent regional tools, refer to Special Tools. Install the 4th gear bearing assembly (1). in!i.l.i-if ...

    Other materials:

    Windows
    Warning Never leave a child, a helpless adult, or a pet alone in a vehicle, especially with the windows closed in warm or hot weather. They can be overcome by the extreme heat and suffer permanent injuries or even death from heat stroke. The vehicle aerodynamics are designed to improve fuel ...

    Fuel Tank Filler Pipe Replacement
    Removal Procedure Remove the bracket fastener (1). Lift and support the vehicle. Refer to Lifting and Jacking the Vehicle. Remove the fuel tank filler pipe bracket fastener (1). Disconnect the vent hose (2). Refer to Plastic Collar Quick C ...

    Heated Oxygen Sensor Replacement - Sensor 1
    Heated Oxygen Sensor Replacement - Sensor 1 Callout Component Name Warning: In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool. Prelimi ...

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