Chevrolet Sonic Repair Manual: 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 pullersand a hydraulic press.
ii
- Remove the following components:
- 1st gear bearing assembly (1)
- 1st/2nd gear inner blocking ring (2)
- 1st/2nd gear intermediate cone ring (3)
- 1st/2nd gear outer blocking ring (4)
Remove and discard the 1st/2nd gear synchronizer assembly
retaining ring (1).
Remove the 1st/2nd gear synchronizer assembly (1) and 2nd
gear assembly (2) as a unit using 69604356 pullersand a hydraulic press.
Separate 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)
Remove the following components:
- 2nd gear bearing assembly (1)
- 3rd gear thrust washer retaining ring (2)
- 3rd gear thrust washer (3)
- 3rd gear assembly (4)
- 3rd gear bearing assembly (5)
- 3rd gear inner blocking ring (6)
- 3rd gear intermediate blocking ring (7)
- 3rd gear outer blocking ring (8)
Remove and discard the 3rd/4th gear synchronizer assembly
retaining ring (1) and the 3rd/4th gear synchronizer assembly thrust washer (2).
Remove the 3rd/4th gear synchronizer assembly (1) and the
4th gear assembly (2) as a unit using 69604356 pullersand a hydraulic press.
Separate the following components:
- 3rd/4th gear synchronizer assembly (1)
- 4th gear outer blocking ring (2)
- 4th gear intermediate blocking ring (3)
- 4th gear inner blocking ring (4)
- 4th gear assembly (5)
Remove the 4th gear bearing assembly (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 ...
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.
...
Other materials:
Engine Oil Pressure Light
Caution
Lack of proper engine oil maintenance can damage the engine. Driving with
the engine oil low can also damage the engine. The repairs would not be covered
by the vehicle warranty. Check the oil level as soon as possible. Add oil if required,
but if the oil level is within the operating ...
Rear Seat Latch Replacement
Rear Seat Latch Replacement
Callout
Component Name
Preliminary Procedures
Remove the rear seat back cushion. Refer to Rear Seat Back Cushion
Removal and Installation.
Remove the rear seat back cushion cover and pad. Refer ...
Drive Range, Third Gear (Gen 1)
As vehicle speed increases and operating conditions become appropriate, the transmission
control module (TCM) processes input signals from the automatic transmission input
and output speed sensors, the throttle position sensor and other vehicle sensors
to determine the precise moment to comman ...
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