Chevrolet Sonic Repair Manual: Gears Cleaning and Inspection (Gen 2)

Chevrolet Sonic Repair Manual / Powertrain / Transmission/Transaxle / Manual / General / 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 exposed to chemicals.

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)
5th Gear Assembly - Driven (5)
5th Gear - Driving (6)

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.
Clean and air dry the oil gallery.
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.
Clean and air dry the oil gallery.
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 Gears and Shaft

Clean the reverse spur gear (1), reverse helical gear (2),

Clean the reverse spur gear (1), reverse helical gear (2), and shaft (5) in a suitable solvent and air dry all the parts.
Inspect the reverse spur gear bushings (4) and reverse helical gear bushings (3) for the following conditions:

Excessive wear
Scoring
Pitting

Replace the reverse gears if the bushings are faulty.

Inspect the reverse gear shaft for the following conditions:

Excessive wear
Scoring
Pitting

Replace the reverse gear shaft if it is faulty.

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 exp ...

Input Shaft Assemble

Special Tools J-840733 Driver For equivalent regional tools, refer to Special Tools. Note: Ensure the input shaft rear bearing retaining ring (2) is placed on the input s ...

Other materials:

DivX VOD
Press DivX VOD. DIVX VIDEO: DivX is a digital video format created by DivX, LLC, a subsidiary of Rovi Corporation. This is an official DivX Certified® device that plays DivX video. See divx.com for more information and software tools on how to convert files into DivX videos. DIVX VID ...

Front Wheel Drive Shaft Seal Replacement - Case Side
Front Wheel Drive Shaft Seal Replacement - Case Side Callout Component Name 1 Front Wheel Drive Shaft Oil Seal Special Tools DT-23129 Universal Seal Remover DT-47790 Seal Installer GE-6125-1B Slide Hamme ...

Shift Control Housing Replacement
Removal Procedure Set the parking brake. Shift the transmission to the Neutral position. Remove the battery tray. Refer to Battery Tray Replacement. Remove the brake master cylinder assembly from the power brake booster. Refer to Master Cylinder Replacement. ...

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