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Chevrolet Sonic Repair Manual: Transmission Disassemble (Gen 2)

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

Special Tools

For equivalent regional tools, refer to Special Tools.


    Attach R-0007758 holding fixture (2) to the transmission.
  1. Attach R-0007758 holding fixture (2) to the transmission.
  2. Attach R-0007758 holding fixture (2) with transmission to the 3-9506289 Universal Adapter (1).


  3. Remove the clutch release bearing (1).

  4. Remove the clutch fork shaft retaining bolt (2).
  5. Remove the clutch fork shaft (1).

  6. Remove the transmission control lever housing bolts (1).
  7. Remove the control lever housing (2) and gasket (3).

  8. Remove the transmission cover bolts (3).
  9. Remove the transmission cover (2) and gasket (1).

  10. Remove the back up lamp switch (1).

  11. Remove the transmission case bolts (3).
  12. Remove the transmission case (2) and gasket (1).
  13. Remove the case magnet (4), may stay with case.

    14. 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.

  14. Remove the reverse gear shaft snap ring (6) if equipped.
  15. Remove the reverse idler gear washer (5), may stay on the reverse idler gear shaft.

  16. Mark the differential bearing adjuster and case (1) before removal.

  17. Remove the differential bearing adjuster lock bolt (1).
  18. Remove the differential bearing adjuster lock (2).

  19. Using S-9407198 differential bearing race wrench remove the front differential bearing adjuster (1).
  20. Remove the front differential bearing retainer O-ring seal (2).

  21. Remove the front differential carrier cover bolts (1).
  22. Remove the differential carrier cover (2) and gasket (3).

  23. Remove the front differential carrier (1).
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-0 ...

Transmission Fluid Drain and Fill
Draining Procedure Note: The fluid check bolt at the front of the transmission may not be opened. The transmission fluid drained out during the pre-delivery inspection ...

Other materials:

Brake Drum Refinishing
Special Tools CH-41013 Rotor Resurfacing Kit CH-42450-A Wheel Hub Resurfacing Kit For equivalent regional tools, refer to Special Tools. Warning: Refer to Brake Dust Warning. The brake drums do not require refinishing as part of routine brake system service. Do not refinis ...

Parking Brake Lever Replacement
Removal Procedure Remove the front floor console. Refer to Front Floor Console Replacement. Ensure that the park brake lever is in the fully released position. Disconnect the electrical connector from the park brake warning lamp switch. Using ONLY HAND TOOL ...

Manual Shift Shaft and Seal Replacement
Special Tools DT-45201 Cooler Line Seal Remover DT-49101 Seal Installer For equivalent regional tools, refer to Special Tools. Removal Procedure Remove the battery tray. Refer to Battery Tray Replacement. Remove the manual shaft and position switch assembly. Refer ...

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