Chevrolet Sonic Repair Manual: Transmission Assemble (Gen 2)

Chevrolet Sonic Repair Manual / Powertrain / Transmission/Transaxle / Manual / General / Transmission Assemble (Gen 2)

Special Tools

3-9506289 Universal Adapter
R-0007758 Holding Fixture
S-9407197 Differential Rotating Tool
S-9407198 Differential Bearing Race Wrench

For equivalent regional tools, refer to Special Tools.

Install the clutch and differential housing assembly (1)

Install the clutch and differential housing assembly (1) onto the R-0007758 holding fixture.

Install the front differential carrier (1).

Install the gasket (3) and differential carrier cover (2).
Install the front differential carrier cover bolts (1). Tighten to 7 Y (61.96 lb in)
.

Lubricate the O-ring seal (2) with multipurpose grease and install onto the differential bearing adjuster (1).
Lubricate the threads on the differential bearing adjuster with multipurpose grease.
Using S-9407198 differential bearing race wrench install the front differential bearing adjuster (1).

Note:

If all the components are re-used align adjuster to marks. If any component was replaced go to the next step.

Align marks on the differential bearing adjuster and case (1).

Note:

If no components were replaced, the bearing adjuster can be aligned to the marks. If any component was replaced, the following procedure must be performed.

Using the S-9407197 differential rotating tool and a torque wrench, rotate the differential (1) 1 revolution per second.
The breakaway bearing torque should be:

Re-use bearing ?#8201;60?00 Ncm
New Bearing ?#8201;150?10 Ncm

Using the S-9407198 bearing race wrench and the R-0007761 handle, adjust the breakaway torque by tightening or loosing the differential bearing adjuster.

Install the differential bearing adjuster lock (2).

Apply thread locking compound and install the differential bearing adjuster lock bolt (1). Tighten to 9 Y (79.66 lb in)

Install the back up lamp switch (1). Tighten to 20 Y (14.75 lb ft)

Install the reverse idler gear washer (5).

Note:

The reverse gear shaft snap ring (6) MUST be installed even if not originally equipped to prevent shifting issues caused by incorrect assembly or parts not in position.

Install the reverse gear shaft snap ring (6).

Verify fork alignment before installation.

Install the case .

Install the gasket (1) and transmission case (2).

Install the transmission case bolts (3). Tighten to 15 Y (11 lb ft)

Install the gasket (4) and transmission cover (3).

Install the long transmission cover bolts (2). Tighten to 24 Y (18 lb ft)

Install the short transmission cover bolts (1). Tighten to 8 Y (71 lb in)

Install the clutch release bearing (1).

Install the gasket (3) and control lever housing (2).

Install the transmission control lever housing bolts (1). Tighten to 12 Y (106 lb in)

Install the clutch fork shaft (1).

Install the clutch fork shaft retaining bolt (2). Tighten to 35 Y (26 lb ft)

Remove the R-0007758 holding fixture (2) and the 3-9506289 Universal Adapter (1).

Transmission Assemble (Gen 1)

Special Tools 3-9506289 Universal Adapter R-0007758 Holding Fixture S-9407197 Differential Rotating Tool S-9407198 Differential Bearing Race Wrench For equivalent regional tools, refer ...

Transmission Case Assemble (Gen 1)

Special Tools 3-9506289 Universal Adapter J-840733 Driver R-0007758 Holding Fixture R-0007761 Universal Handle R-0007770 Holding Fixture Adapter Plates T-9804669 Seal Installer T-0 ...

Other materials:

Accessories and Modifications
Adding non-dealer accessories or making modifications to the vehicle can affect vehicle performance and safety, including such things as airbags, braking, stability, ride and handling, emissions systems, aerodynamics, durability, and electronic systems like antilock brakes, traction control, a ...

Brake Pedal Pushrod Inspection
Disconnect the brake pedal pushrod (2) from the brake pedal. Reposition the pedal pushrod boot (1) toward the front of the vehicle to expose as much of the pedal pushrod (2) as possible. Inspect the brake pedal pushrod (2) for straightness. If the brake p ...

Manual Transmission Shift Lever and Selector Lever Cable Adjustment
Remove the floor console. Refer to Front Floor Console Replacement. Lift upward and disengage (do not remove) both cable lock adjusters (1) to release the internal cable assembly, one for each side. Block the shift control housing, push the selector lever ( ...

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