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:

Delayed Locking
This feature delays the actual locking of the doors until five seconds after all doors are closed. Delayed locking can only be turned on when the Unlocked Door Anti Lockout feature has been turned off. When is pressed on the driver or passenger door power lock switch while the door is open, ...

Vehicle Data
Capacities and Specifications The following approximate capacities are given in metric and English conversions. See Recommended Fluids and Lubricants for more information. Engine Specifications Engine Drive Belt Routing 1.4L L4 Engine 1.8L L4 Engine (with Air Conditioning) 1. ...

Brake Pressure Modulator Valve Bracket Replacement
Removal Procedure Remove the brake pressure modulator valve (BPMV) and bracket assembly. Refer to Brake Pressure Modulator Valve Replacement. Remove the BPMV bolts (1). Remove the BPMV bracket. Installation Procedure Install the BPMV br ...

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