Chevrolet Sonic Repair Manual: Shift Fork Cleaning and Inspection (Gen 2)

Chevrolet Sonic Repair Manual / Powertrain / Transmission/Transaxle / Manual / Transmission Assembly / Shift Fork Cleaning and Inspection (Gen 2)

Warning:

Wear safety glasses to avoid injury when using compressed air or any cleaning solvent. Bodily injury may occur if fumes are inhaled or if skin is exposed to chemicals.

Clean the following components with a suitable solvent. Air dry all the parts.

3rd and 4th shift fork assembly (1)
5th shift blocking guide (2)
3rd and 4th shift shaft (3)
1st and 2nd shaft block (4)
1st and 2nd shift fork assembly (5)
1st and 2nd shift shaft (6)
5th shift fork assembly (7)
Reverse shift shaft (8)
Reverse shift fork assembly (9)
Reverse fork block (10)

Inspect the following components for excessive wear, fractures or distortion.

3rd and 4th shift fork assembly (1)
5th shift blocking guide (2)
1st and 2nd shift fork assembly (3)
1st and 2nd shaft block (4)
5th shift fork assembly (5)
Reverse shift fork assembly (6)
Reverse fork block (7)

Inspect the shift shaft lever bushings for excessive wear.

Inspect the shift fork nylon inserts (1) for wear.

Replace parts that are fractured, excessively worn, or distorted.

Replace an excessively worn or burred shift shaft.

Shift Fork Cleaning and Inspection (Gen 1)

Warning: Wear safety glasses to avoid injury when using compressed air or any cleaning solvent. Bodily injury may occur if fumes are inhaled or if skin is exposed to chemicals. ...

Synchronizers Assemble

1st/2nd Gear Synchronizer iv Note: When servicing the synchronizers, retain them in the same order that they are removed. Keep the synchronizer components together ...

Other materials:

Dome Lamps
The dome lamp controls are in the headliner above the rear seats. (Dome Lamp Override): Press to turn the lamps off, even when a door is open. (Door): When the button is returned to the middle position, the lamps turn on automatically when a door is opened. | (On): Press to turn on the dom ...

Front Side Door Window Switch Replacement (Left Side)
Front Side Door Window Switch Replacement Callout Component Name Preliminary Procedure Remove the front side door window switch bezel. Refer to Front Side Door Window Switch Bezel Replacement. 1 ...

Brake Rotor Assembled Lateral Runout Measurement
Special Tools CH-41013 Rotor Surfacing Kit CH-42450-A Wheel Hub Resurfacing Kit CH-45101 Hub and Wheel Runout Gauge CH-45101-100 Conical Brake Rotor Washers For equivalent regional tools, refer to Special Tools. Warning: Refer to Brake Dust Warning. Note: B ...

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