Chevrolet Sonic Repair Manual: Main Shaft Disassemble (Gen 1)
| Table 1: | 1st Gear Removal |
| Table 2: | 1st Gear Blocking Rings Removal |
| Table 3: | 1st and 2nd Gear Synchronizer Hub Retaining Ring Removal |
| Table 4: | 1st and 2nd Gear Synchronizer Hub and 2nd Gear Removal |
| Table 5: | 2nd Gear Bearing Removal |
| Table 6: | 3rd Gear Removal |
| Table 7: | 3rd and 4th Gear Synchronizer Hub Retaining Ring Removal |
| Table 8: | 3rd and 4th Gear Thrust Washer Removal |
| Table 9: | 3rd and 4th Gear Synchronizer Hub and 4th Gear Removal |
| Table 10: | 4th Gear Bearing Removal |
- 1st Gear Removal
1st Gear Removal Callout
Component Name
Preliminary Procedure
A hydraulic press is required to complete procedure. Prepare hydraulic press for procedure.
1
1st Gear Thrust Washer
Special Tools- DT-307-B Remover Plate
- DT-736 Clutch Arbor
2
1st Gear
- 1st Gear Blocking Rings Removal
1st Gear Blocking Rings Removal Callout
Component Name
1
1st Gear Bearing
2
1st Gear Inner Blocking Ring
3
1st Gear Intermediate Blocking Ring
4
1st Gear Outer Blocking Ring
- 1st and 2nd Gear Synchronizer Hub Retaining Ring Removal
1st and 2nd Gear Synchronizer Hub Retaining Ring Removal Callout
Component Name
1
1st and 2nd Gear Synchronizer Hub Retaining Ring
Special Tools
GE-8059 Snap Ring Pliers
- 1st and 2nd Gear Synchronizer Hub and 2nd Gear Removal
1st and 2nd Gear Synchronizer Hub and 2nd Gear Removal Callout
Component Name
Preliminary Procedure
A hydraulic press is required to complete procedure. Prepare hydraulic press for procedure.
1
2nd Gear
Special Tools- DT-307-B Remover Plate
- DT-736 Clutch Arbor
- 2nd Gear Bearing Removal
2nd Gear Bearing Removal Callout
Component Name
1
1st and 2nd Gear Synchronizer Hub Retaining Ring
2
2nd and 3rd Gear Thrust Washer
3
2nd Gear Bearing
- 3rd Gear Removal
3rd Gear Removal Callout
Component Name
1
3rd Gear
2
3rd Gear Bearing
- 3rd and 4th Gear Synchronizer Hub Retaining Ring Removal
3rd and 4th Gear Synchronizer Hub Retaining Ring Removal Callout
Component Name
1
3rd and 4th Gear Synchronizer Hub Retaining
Special Tools
GE-8059 Snap Ring Pliers
- 3rd and 4th Gear Thrust Washer Removal
3rd and 4th Gear Thrust Washer Removal Callout
Component Name
1
3rd and 4th Gear Synchronizer Hub Retaining Ring
Special Tools
GE-8059 Snap Ring Pliers
- 3rd and 4th Gear Synchronizer Hub and 4th Gear Removal
3rd and 4th Gear Synchronizer Hub and 4th Gear Removal Callout
Component Name
Preliminary Procedure
A hydraulic press is required to complete procedure. Prepare hydraulic press for procedure.
1
3rd and 4th Gear Synchronizer Hub
Special Tools- DT-307-B Remover Plate
- DT-736 Clutch Arbor
2
4th Gear
- 4th Gear Bearing Removal
4th Gear Bearing Removal Callout
Component Name
1
4th Gear Bearing
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).
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...
Main Shaft Disassemble (Gen 2)
Special Tools
69604356 Gear Pullers
For equivalent regional tools, refer to Special Tools.
Remove the 1st gear thrust washer (1) and the 1st gear (2)
using 69604356 pull ...
Other materials:
Front Wheelhouse Liner Inner Front Extension Replacement (Right Side, LUV)
Front Wheelhouse Liner Inner Front Extension Replacement
Callout
Component Name
Preliminary Procedure
Remove the tire and wheel assembly. Refer to Tire and Wheel Removal
and Installation.
Remove the front fascia opening l ...
Air Conditioning Compressor Replacement (LUV)
Air Conditioning Compressor Replacement
Callout
Component Name
Preliminary Procedure
Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
Raise and support the vehicle. Refer to Lifting and Jacking the
...
Ignition and Start Switch Housing Replacement
Ignition and Start Switch Housing Replacement
Callout
Component Name
Preliminary Procedures
Remove the theft deterrent module. Refer to Theft Deterrent Module
Replacement.
Remove the turn signal switch bracket. Refer to T ...
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