Chevrolet Sonic Repair Manual: Main Shaft Disassemble (Gen 2)

Chevrolet Sonic Repair Manual / Powertrain / Transmission/Transaxle / Manual / General / 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)

Remove the 1st gear thrust washer (1) and the 1st gear (2) using 69604356 pullersand a hydraulic press.

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).

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 ...

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. ...

Other materials:

Inspection/Maintenance (I/M) System DTC Table
Inspection/Maintenance (I/M) System DTC Table System DTCs Required to Set System Status to YES If an inspection/maintenance system status indicator did not update to yes during the Inspection/Maintenance Complete System Set Pro ...

Transmission Fluid Pump, Front Differential Carrier Baffle, and Front Differential Ring Gear Removal (6T40/45)
Transmission Fluid Pump, Front Differential Carrier Baffle, and Front Differential Ring Gear Removal Callout Component Name 1 Front Differential Carrier Baffle Bolts M6 x 25 (Qty: 2) ...

Range Selector Lever Cable Adjustment
Note: Adjust the automatic transmission range selector cable while the transmission and the gear selector are in the Park position only. Failure to do so may cause mis-adjustment. Set the park brake and chock the wheels. Verify the transmission range select lever is in the par ...

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