Chevrolet Sonic Repair Manual: Transmission Case Assemble (Gen 2)
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-0307000 Extractor and Driver Fixture
For equivalent regional tools, refer to Special Tools.
- Install the reverse helical gear washer (3) onto the reverse
idler gear shaft.
- Install the reverse idler gear shaft retaining ball (2).
- Install the reverse idler gear shaft (1).
- Using T-9804669 seal installer (2) and R-0007761
handle (1), install the mainshaft bearing (3) into the case.
- Install the mainshaft bearing retaining ring (1).
- Install the following components onto the T-0307000
driver fixture with top plate removed.
- Main shaft (2)
- Reverse helical gear (5)
- Reverse synchro assembly (4)
- Reverse spur gear (3)
- Input Shaft (6)
Note:
While pressing, pay attention to the input shaft bearing retaining
ring, because it can be pressed into the first gear.
Guide the shafts (1?) into the bores, and support the reverse
idler gear (3) while pressing into the case.
Using the T-0307000 driver fixture, press the 5th gear
bearing race (1) onto the mainshaft.
Note:
The reverse gear shaft snap ring (3) MUST be installed even
if not originally equipped to prevent shifting issues caused by incorrect assembly
or parts not in position.
Install the reverse spur gear bearing (1), reverse spur gear
washer (2), and reverse gear shaft snap ring (3).
Install the case and shafts assembly onto the R-0007770 adapter plates (1)
and R-0007758 holding fixture (2).
Install the input shaft bearing retaining ring (1).
Install the 1st and 2nd shaft block (2).
Install the 1st and 2nd shaft block pin (3) to the dimension ??depth of
2 mm (0.80 in).
Install the 1st and 2nd shift fork (4).
Install the 1st and 2nd shift shaft (1).
Install the 1st and 2nd shift fork pin (5) to the dimension ??depth of
2 mm (0.80 in).
Install the gearshift rod (1) into the transmission case.
Install the 5th shift blocking guide (1) into the transmission case.
Install the 3rd and 4th shift fork (2).
Install the 3rd and 4th shift shaft (1).
Install the 3rd and 4th shift fork pin (3) to the dimension ??depth of
2 mm (0.80 in).
Install the reverse fork block (1).
Install the reverse fork block pin (2) to the dimension ??depth of 2 mm
(0.80 in).
Install the reverse shift fork (5).
Install the reverse shift shaft (3).
Install the reverse shift fork pin (4) to the dimension ??depth of 2 mm
(0.80 in).
Using a plastic hammer or equivalent install the 4 shift shaft detent sleeves (1?)
into the transmission case until they stop.
Note:
Engage the shift shafts into 2nd gear, 5th gear, and 3rd gear
as indicated with arrows to install the interlock pin connector.
Install the shift shaft interlock pin connector (1).
Using thread locking compound install the shift shaft interlock pin connector
bolts (2) and tighten to 7 Y (62 lb in).
Note:
Move shift forks into neutral position.
Install the parking pawl (2).
Caution:
Refer to Fastener Caution.
Using thread locking compound install the parking pawl retaining bolts (1) and
tighten to 7 Y (62 lb in).
Remove case and shafts assembly from R-0007770 adapter plates and install
onto T-0307000 driver fixture.
Using J-840733 driver, press the 5th gear, driving (1) onto the input
shaft.
Install a NEW 5th gear retaining ring (1).
Install the 5th gear bearing assembly (3).
Install the 5th gear assembly, driven (2).
Install the 5th gear blocking ring (1).
Ensure that the synchronizer assembly (1) is functioning properly, refer to
Synchronizers Cleaning and Inspection and
Synchronizers Assemble.
Using the J-840733 driver and a press, install the 5th gear synchronizer
assembly (1).
Install the 5th gear sychronizing hub retaining ring (1).
Remove the case and shafts assembly from the T-0307000 driver fixture.
Install R-0007770 adapter plates (1) onto case (2) and then attach to
R-0007758 holding fixture (3).
Install the 5th shift fork shoes (3).
Install the 5th shift fork bracket assembly (2).
Using thread locking compound install the 5th shift fork bracket bolts (1) and
tighten to 22 Y (16 lb ft).
Remove the transmission case, from the R-0007770 adapter plates (1) the
R-0007758 holding fixture and 3-9506289 adapter.
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 ...
Special Tools
3-9506289 Universal Adapter
J-810700 Mainshaft Bearing Remover
J-810704 Center Bar Puller
M-680770 Universal Sliding Mallet
R-0007758 Holding Fixture
R-0007770 Holding F ...
Other materials:
Radio
Radio Controls without Touchscreen
: Press to turn the system on or
off.
Turn to increase or decrease the volume.
When the system is on, press and release to mute the system. Press and release
again to turn the sound back on.
RADIO/BAND: Press to choose FM, AM, or SiriusXM® (if equipped).
...
Interior Care
To prevent dirt particle abrasions, regularly clean the vehicle's interior. Immediately
remove any soils. Note that newspapers or dark garments that can transfer color
to home furnishings can also permanently transfer color to the vehicle's interior.
Use a soft bristle brush to remove d ...
Steering Column Lower Trim Cover Replacement
Steering Column Lower Trim Cover Replacement
Callout
Component Name
Preliminary Procedure
Remove the instrument panel steering column upper trim cover. Refer to
Steering Column Upper Trim Cover Replacement.
...
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