Chevrolet Sonic Repair Manual: Differential Case Assemble
Special Tools
- J-810721 Axle Shaft Seal Remover Support Base
- R-0407011 Bearing Race Remover
- R-0407012 Differential Carrier Cone Bearing Cap Driver
- R-0007761 Universal Handle for Pullers and Installers
- S-9407194 Speed Sensor Impeller Ring Installer
- S-9407195 Pinion Gear Case Bearing Installer
- S-9707500 Seal Installer
For equivalent regional tools, refer to Special Tools.
- Install the front differential pinion and side gear thrust washer. It must be possible to insert the collar (1) of the thrust washer into the guide for the pinion gears in the housing.
- Install the front differential pinion gears (3) and side gears (4).
- Install the front differential pinion gear shaft (2) and the pinion gear shaft retaining washers (1).
- If both components are reused align the assembly marks (3).
- Install the front differential ring gear (2).
- Install the front differential ring gear bolts (1). Tighten
to 90 N? (66.4 lb ft)
.
- Install the ring front wheel speed sensor reluctor wheel (1) using the S-9407194 installer and a hydraulic press.
- Install the front differential bearing assemblies (1) using the S-9407195 installer and a hydraulic press.
- Install the front wheel drive shaft oil seal (3) using the R-0007761 handle (1), S-9707500 seal installer (2), and the J-810721 support base (4).
- Install the front differential bearing race (3) using the R-0007761 handle (1) and the R-0407012 driver (2).
Note:
Lubricate rotating parts on their bearing, running, seating, and pressure surfaces using transmission fluid.
Warning:
Refer to Safety Glasses Warning.
Clutch and Differential Housing Disassemble
Special Tools
M-680770 Universal Sliding Mallet
R-0007758 Holding Fixture
R-0407008 Counter Shaft Bearing Remover
R-0407010 Input Shaft Needle Bearing Puller and Driver
R-0407013 Gearshi ...
Differential Case Disassemble
Special Tools
6-9607346 Sensor Ring Gear Puller
J-810704 Steering Column Center Bar Puller
J-810721 Axle Shaft Seal Remover Support Base
R-0006749 Support Base
R-0407011 Bearing Race Rem ...
Other materials:
Taillamps, Turn Signal, Stoplamps, and Back-Up Lamps
Sedan Taillamp Shown, Hatchback Taillamp Similar
1. Back-up Lamp
2. Turn Signal Lamp
3. Stop Lamp/Taillamp
4. Sidemarker Lamp
To replace one of these bulbs:
1. Open the trunk.
2. Remove the two screws, which secure the taillamp assembly.
3. Remove the taillamp assembly by pulling it stra ...
Tire-to-Wheel Match-Mounting (Vectoring)
Note: After remounting a tire to a wheel or after replacing a tire
and/or a wheel, remeasure the tire and wheel assembly runout in order to verify
that the amount of runout has been reduced and brought to within tolerances.
Ensure that the tire and wheel assembly is properly balanced ...
Water Pump Installation
Clean the sealing surfaces and the 3 coolant pump threads.
Install NEW gasket.
Caution: Refer to Fastener Caution.
Caution: Refer to Torque-to-Yield Fastener Caution.
Install the coolant pump (1).
Install 5 NEW bolts (2) and tighten to 8& ...
0.009