Chevrolet Sonic manuals

Chevrolet Sonic Repair Manual: Main Shaft Disassemble (Gen 1)

Table 1: 1st Gear Removal
Table 2: 1st Gear Blocking Rings Removal
Table 3: 1st and 2nd Gear Synchronizer Hub Retaining Ring Removal
Table 4: 1st and 2nd Gear Synchronizer Hub and 2nd Gear Removal
Table 5: 2nd Gear Bearing Removal
Table 6: 3rd Gear Removal
Table 7: 3rd and 4th Gear Synchronizer Hub Retaining Ring Removal
Table 8: 3rd and 4th Gear Thrust Washer Removal
Table 9: 3rd and 4th Gear Synchronizer Hub and 4th Gear Removal
Table 10: 4th Gear Bearing Removal
1st Gear Removal


1st Gear Removal

Callout

Component Name

Preliminary Procedure

A hydraulic press is required to complete procedure. Prepare hydraulic press for procedure.

1

1st Gear Thrust Washer

Special Tools

  • DT-307-B Remover Plate
  • DT-736 Clutch Arbor

2

1st Gear

1st Gear Blocking Rings Removal


1st Gear Blocking Rings Removal

Callout

Component Name

1

1st Gear Bearing

2

1st Gear Inner Blocking Ring

3

1st Gear Intermediate Blocking Ring

4

1st Gear Outer Blocking Ring

1st and 2nd Gear Synchronizer Hub Retaining Ring Removal


1st and 2nd Gear Synchronizer Hub Retaining Ring Removal

Callout

Component Name

1

1st and 2nd Gear Synchronizer Hub Retaining Ring

Special Tools

GE-8059 Snap Ring Pliers

1st and 2nd Gear Synchronizer Hub and 2nd Gear Removal


1st and 2nd Gear Synchronizer Hub and 2nd Gear Removal

Callout

Component Name

Preliminary Procedure

A hydraulic press is required to complete procedure. Prepare hydraulic press for procedure.

1

2nd Gear

Special Tools

  • DT-307-B Remover Plate
  • DT-736 Clutch Arbor
2nd Gear Bearing Removal


2nd Gear Bearing Removal

Callout

Component Name

1

1st and 2nd Gear Synchronizer Hub Retaining Ring

2

2nd and 3rd Gear Thrust Washer

3

2nd Gear Bearing

3rd Gear Removal


3rd Gear Removal

Callout

Component Name

1

3rd Gear

2

3rd Gear Bearing

3rd and 4th Gear Synchronizer Hub Retaining Ring Removal


3rd and 4th Gear Synchronizer Hub Retaining Ring Removal

Callout

Component Name

1

3rd and 4th Gear Synchronizer Hub Retaining

Special Tools

GE-8059 Snap Ring Pliers

3rd and 4th Gear Thrust Washer Removal


3rd and 4th Gear Thrust Washer Removal

Callout

Component Name

1

3rd and 4th Gear Synchronizer Hub Retaining Ring

Special Tools

GE-8059 Snap Ring Pliers

3rd and 4th Gear Synchronizer Hub and 4th Gear Removal


3rd and 4th Gear Synchronizer Hub and 4th Gear Removal

Callout

Component Name

Preliminary Procedure

A hydraulic press is required to complete procedure. Prepare hydraulic press for procedure.

1

3rd and 4th Gear Synchronizer Hub

Special Tools

  • DT-307-B Remover Plate
  • DT-736 Clutch Arbor

2

4th Gear

4th Gear Bearing Removal


4th Gear Bearing Removal

Callout

Component Name

1

4th Gear Bearing

Main Shaft Assemble (Gen 2)
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). in!i.l.i-if ...

Main Shaft Disassemble (Gen 2)
Special Tools 69604356 Gear Pullers For equivalent regional tools, refer to Special Tools. Remove the 1st gear thrust washer (1) and the 1st gear (2) using 69604356 pull ...

Other materials:

Rear Window Wiper Arm Replacement
Rear Window Wiper Arm Replacement Callout Component Name Preliminary Procedure Using a small flat-bladed tool, release the locking tabs and lift the end of the wiper arm nut cover in order to access and remove the rear wipe ...

Torque Steer Description
A vehicle pulls or leads in one direction during hard acceleration. A vehicle pulls or leads in the other direction during deceleration. The following factors may cause torque steer to be more apparent on a particular vehicle: A slightly smaller diameter tire on the right front increa ...

Relay Replacement (Within an Electrical Center)
Special Tools EL-43244 Relay Puller Pliers Removal Procedure Remove the electrical center cover. Note: Always note the orientation of the relay. If equipped with a notch style relay; observe the location of the notch on the old relay to verify the new r ...

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