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).
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.
- Assemble the following components:
- 3rd/4th gear synchronizer assembly (1)
- 3rd gear blocking ring (3)
- 4th gear assembly (4)
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:
- 3rd gear blocking ring (6)
- 3rd gear bearing assembly (5)
- 3rd gear assembly (4)
- 3rd gear thrust washer (3)
- 3rd gear thrust washer retaining ring (2)
- 2nd gear bearing assembly (1)
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:
- 1st/2nd gear synchronizer assembly (1)
- 1st/2nd gear outer blocking ring (2)
- 1st/2nd gear intermediate cone ring (3)
- 1st/2nd gear inner blocking ring (4)
- 2nd gear assembly (5)
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:
- 1st/2nd gear outer blocking ring (5)
- 1st/2nd gear intermediate cone ring (4)
- 1st/2nd gear inner blocking ring (3)
- 1st gear bearing assembly (2)
- 1st gear (1)
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.
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 ...
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).
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Other materials:
Front Seat Outboard Seat Back Airbag Replacement
Front Seat Outboard Seat Back Airbag Replacement
Callout
Component Name
Warning: Following the deployment of a side impact air bag,
inspect the following parts for damage. Replace these parts if necessary:
...
Engine Front Cover Gasket Installation
Clean the sealing surfaces and remove all remains of old sealing compound
material.
Note: The thickness of the sealing bead should be 2 mm (0.0787 in).
Apply sealing compound to the shown areas (1) and (2). Refer to Adhesives,
Fluids ...
Engine Oil Cooler Installation
Note: Lubricate the oil cooler seal (8) with clean engine oil.
Install the engine oil cooler assembly (6) along with 2 NEW sealings (8)
and (9).
Install the 3 oil cooler bolts (5) and tighten to 10 Y (89 l ...
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