Chevrolet Sonic Repair Manual: Shift Fork Cleaning and Inspection (Gen 1)

Chevrolet Sonic Repair Manual / Powertrain / Transmission/Transaxle / Manual / Transmission Assembly / Shift Fork Cleaning and Inspection (Gen 1)

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 components with a suitable solvent. Air dry all the parts.

3rd and 4th shift fork assembly (1)
5th shift blocking guide (2)
3rd and 4th shift shaft (3)
1st and 2nd shift fork assembly (4)
1st and 2nd shift shaft (5)
5th shift fork assembly (6)
Reverse shift shaft (7)
Reverse shift fork assembly (8)

Inspect the following components for excessive wear, fractures or distortion.

3rd and 4th shift fork assembly (1)
5th shift blocking guide (2)
1st and 2nd shift fork assembly (3)
5th shift fork assembly (4)
Reverse shift fork assembly (5)

Inspect the shift shaft lever bushings for excessive wear.

Inspect the shift fork nylon inserts (1) for wear.

Replace parts that are fractured, excessively worn, or distorted.

Replace an excessively worn or burred shift shaft.

Transmission Assembly

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Shift Fork Cleaning and Inspection (Gen 2)

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. ...

Other materials:

Special Tools
Illustration Tool Number/ Description CH-161-B DT-161-B KM-161-B J-22888-20A Bearing Puller CH-804 CH-49692 MKM-804 Tensioner CH-39570 J-39570 ...

Steering Wheel Horn Contact Replacement
Steering Wheel Horn Contact Replacement Callout Component Name Preliminary Procedure Remove the steering wheel inflatable restraint module. Refer to Airbag Steering Wheel Module Replacement. 1 S ...

Tire and Wheel Assembly Runout Measurement - On-Vehicle
Raise and support the vehicle. Closely inspect each tire for proper and even bead seating. If any of the tire beads were not properly or evenly seated, reseat the tire bead, then proceed to step 4. Refer to Tire and Wheel Removal and Installation. Wrap the circumferenc ...

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