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:

Instrument Panel Lower Intermediate Reinforcement Replacement
Instrument Panel Lower Intermediate Reinforcement Replacement Callout Component Name Preliminary Procedures Disable the SIR system. Refer to SIR Disabling and Enabling. Remove the passenger inflatable restraint instrument ...

Shoulder Belt Replacement - Rear (Hatchback)
Shoulder Belt Replacement - Rear Callout Component Name Preliminary Procedures Remove the rear seat cushion. Refer to Rear Seat Cushion Removal and Installation. Remove the body lock pillar upper trim. Refer to Body Lock ...

Electronic Ignition System Description
Electronic Ignition System Operation The electronic ignition system produces and controls the high energy secondary spark. This spark ignites the compressed air/fuel mixture at precisely the correct time, providing optimal performance, fuel economy, and control of exhaust emissions. ...

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