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Chevrolet Sonic Repair Manual: Gears Cleaning and Inspection (Gen 1)

Chevrolet Sonic Repair Manual / Powertrain / Transmission/Transaxle / Manual / General / Gears Cleaning and Inspection (Gen 1)

Gears


    Warning:

    Wear safety glasses to avoid injury when using compressed air or any cleaning solvent. Bodily injury may occur if fumes are inhaled or if skin is exposed to chemicals.

  1. Clean the following gears in a suitable solvent and air dry all the parts.
  • 1st gear (1)
  • 2nd gear assembly (4)
  • 3rd gear assembly (3)
  • 4th gear assembly (2)
  • Reverse idler gear (5)
  • Inspect the gear tooth surfaces on all the gears for the following conditions:
    • Cracks
    • Pitting
    • Nicks
    • Chipped gear teeth
    • High spots ?small shiny spots on the gear teeth mating surfaces
    Input Shaft

      Clean the input shaft (1) in a suitable solvent.
    1. Clean the input shaft (1) in a suitable solvent.
    2. Clean and air dry the oil gallery.
    3. Inspect the input shaft bearing surfaces for the following conditions:
    • Wear
    • Lack of lubricant
    • Debris embedded in the oil grooves
    • Brinelling
  • Inspect the input shaft splines for wear or damage.
  • Replace the input shaft if any of the above conditions are found.
    • Main Shaft

      Clean the main shaft (1) in a suitable solvent.
    1. Clean the main shaft (1) in a suitable solvent.
    2. Clean and air dry the oil gallery.
    3. Inspect the main shaft bearing surfaces for the following conditions:
    • Wear
    • Lack of lubricant
    • Debris embedded in the oil grooves
    • Brinelling
  • Inspect the main shaft splines for wear or damage.
  • Replace the main shaft if any of the above conditions are found.
    • Reverse Idler Gear and Shaft

      Clean the reverse idler gear (1) and shaft (2) in
    1. Clean the reverse idler gear (1) and shaft (2) in a suitable solvent and air dry all the parts.
    2. Inspect the reverse idler gear bushing (3) for the following conditions:
    • Excessive wear
    • Scoring
    • Pitting
  • Replace the reverse idler gear if the bushing is faulty.
  • Inspect the reverse idler gear shaft for the following conditions:
    • Excessive wear
    • Scoring
    • Pitting
  • Replace the reverse idler gear shaft if it is faulty.
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    Gears Cleaning and Inspection (Gen 2)
    Gears Warning: Wear safety glasses to avoid injury when using compressed air or any cleaning solvent. Bodily injury may occur if fumes are inhaled or if skin is exp ...

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