Chevrolet Sonic Repair Manual: Transmission Disassemble (Gen 1)
Special Tools
- 3-9506289 Universal Adapter
- R-0007758 Holding Fixture
- S-9407198 Differential Bearing Race Wrench
For equivalent regional tools, refer to Special Tools.
- Attach R-0007758 holding fixture (2) to the transmission.
- Attach R-0007758 holding fixture (2) with transmission to the 3-9506289 Universal Adapter (1).
- Remove the clutch release bearing (1).
- Remove the clutch fork shaft retaining bolt (2).
- Remove the clutch fork shaft (1).
- Remove the transmission control lever housing bolts (1).
- Remove the control lever housing (2) and gasket (3).
- Remove the transmission cover bolts (3).
- Remove the transmission cover (2) and gasket (1).
- Remove the back up lamp switch (1).
- Remove the transmission case bolts (3).
- Remove the transmission case (2) and gasket (1).
- Remove the case magnet (4), may stay with case.
- Remove the reverse idler gear washer (5), may stay on the reverse idler gear shaft.
- Mark the differential bearing adjuster and case (1) before removal.
- Remove the differential bearing adjuster lock bolt (1).
- Remove the differential bearing adjuster lock (2).
- Using S-9407198 differential bearing race wrench remove the front differential bearing adjuster (1).
- Remove the front differential bearing retainer O-ring seal (2).
- Remove the front differential carrier cover bolts (1).
- Remove the differential carrier cover (2) and gasket (3).
- Remove the front differential carrier (1).
Transmission Control Replacement
Removal Procedure
Remove the floor console. Refer to
Front Floor Console Replacement.
Lift both cable adjustment retainers (1), one for
each cable, to release the s ...
Transmission Disassemble (Gen 2)
Special Tools
3-9506289 Universal Adapter
R-0007758 Holding Fixture
S-9407198 Differential Bearing Race Wrench
For equivalent regional tools, refer to Special Tools.
Attach R-0 ...
Other materials:
Brake Rotor Assembled Lateral Runout Correction
Note:
Brake rotor thickness variation MUST be checked BEFORE checking for
assembled lateral runout (LRO). Thickness variation exceeding the maximum
acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness
Variation Measurement.
Brake rotor assembled latera ...
Engine Coolant Thermostat Installation
Caution: Refer to Engine Coolant Thermostat Housing Caution.
Clean the engine coolant sealing surfaces.
Install the engine coolant seal (1).
Install the engine coolant thermostat assembly (2).
Caution: Refer to Fastener Caution.
Install the 4R ...
Exhaust Rear Muffler Heat Shield Replacement
Exhaust Rear Muffler Heat Shield Replacement
Callout
Component Name
Preliminary Procedure
Disconnect the exhaust system hangers in the rear and allow the exhaust
system to rest on the rear axle.
1
...
0.005