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:

Lane Departure Warning (LDW) Light
This light comes on briefly while starting the vehicle. If it does not, have the vehicle serviced by your dealer. If the system is working normally, the light then turns off. This light comes on green when the system is on and ready to operate. When the system determines that the vehicle is ...

Washing the Vehicle
To preserve the vehicle's finish, wash it often and out of direct sunlight. Caution Do not use petroleum-based, acidic, or abrasive cleaning agents as they can damage the vehicle's paint, metal, or plastic parts. If damage occurs, it would not be covered by the vehicle warranty. Approv ...

Front Brake Shield Replacement
Removal Procedure Warning: Refer to Brake Dust Warning. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. Remove the front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation. Remove the front brake rotor. Refer to ...

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