Chevrolet Sonic Repair Manual: Main Shaft Assemble (Gen 1)
Special Tools
3-0207944 Main Shaft Tapered Bearing Insert Tool
For equivalent regional tools, refer to Special Tools.
- Install the 4th gear bearing assembly (1).
Note:
The 3rd gear blocking ring lugs must be aligned with the
3rd/4th gear synchronizer assembly grooves.
Note:
The groove on the 3rd/4th gear synchronizer assembly (2)
should point toward the 4th gear assembly.
- Assemble the following components:
- 3rd/4th gear synchronizer assembly (1)
- 3rd gear blocking ring (3)
- 4th gear assembly (4)
Install the 3rd/4th gear synchronizer assembly (2) and the
4th gear assembly (1) as a unit using 3-0207944 bearing insert tool (3)
and a hydraulic press.
Install the 3rd/4th gear synchronizer assembly thrust washer (2)
and the NEW 3rd/4th gear synchronizer assembly retaining ring (1).
Install the following components:
- 3rd gear blocking ring (6)
- 3rd gear bearing assembly (5)
- 3rd gear assembly (4)
- 3rd gear thrust washer (3)
- 3rd gear thrust washer retaining ring (2)
- 2nd gear bearing assembly (1)
Note:
The lugs on the blocking rings must be aligned with the 2nd
gear assembly and the 1st/2nd gear synchronizer assembly.
Assemble the following components:
- 1st/2nd gear synchronizer assembly (1)
- 1st/2nd gear outer blocking ring (2)
- 1st/2nd gear intermediate cone ring (3)
- 1st/2nd gear inner blocking ring (4)
- 2nd gear assembly (5)
Install the 1st/2nd gear synchronizer assembly (2) and the
2nd gear assembly (1) as a unit using 3-0207944 bearing insert tool (3)
and a hydraulic press.
Install the NEW 1st/2nd gear synchronizer assembly retaining
ring (1).
Note:
The lugs on the blocking rings must be aligned with the 1st/2nd
gear synchronizer assembly grooves.
Install the following components:
- 1st/2nd gear outer blocking ring (5)
- 1st/2nd gear intermediate cone ring (4)
- 1st/2nd gear inner blocking ring (3)
- 1st gear bearing assembly (2)
- 1st gear (1)
Install the 1st gear thrust washer (1) and the thrust washer (2) in the 1st/2nd
gear synchronizer assembly using a suitable tube (3) and a hydraulic press.
Note: The input shaft rear bearing retaining ring (2) remains
loose on the shaft.
Remove the input shaft rear bearing assembly (1) using
a hydraulic press.
Rem ...
Special Tools
3-0207944 Main Shaft Tapered Bearing Insert Tool
For equivalent regional tools, refer to Special Tools.
Install the 4th gear bearing assembly (1).
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Other materials:
Vehicle Identification Number (VIN)
This legal identifier is in the front corner of the instrument panel, on the
left side of the vehicle. It can be seen through the windshield from outside. The
VIN also appears on the Vehicle Certification and Service Parts labels and certificates
of title and registration.
Engine Identifi ...
Wheel Stud Replacement
Special Tools
CH 43631 Ball Joint Separator
For equivalent regional tools, refer to Special Tools.
Removal Procedure
Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
Remove the tire and wheel assembly. Refer to Tire and Wheel Removal
and In ...
Warm Up Three-Way Catalytic Converter Removal
Disconnect the heated oxygen sensor wiring harness (3) from retainer clip.
Remove the 2 catalytic converter to catalytic converter bracket nuts (4)
and (6).
Loosen the three way warm up catalytic converter V-clamp (1).
Remove the three way warm up ...
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