Chevrolet Sonic Repair Manual: Shift Fork Cleaning and Inspection (Gen 2)

Chevrolet Sonic Repair Manual / Powertrain / Transmission/Transaxle / Manual / Transmission Assembly / 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.

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 shaft block (4)
1st and 2nd shift fork assembly (5)
1st and 2nd shift shaft (6)
5th shift fork assembly (7)
Reverse shift shaft (8)
Reverse shift fork assembly (9)
Reverse fork block (10)

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)
1st and 2nd shaft block (4)
5th shift fork assembly (5)
Reverse shift fork assembly (6)
Reverse fork block (7)

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.

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. ...

Synchronizers Assemble

1st/2nd Gear Synchronizer iv Note: When servicing the synchronizers, retain them in the same order that they are removed. Keep the synchronizer components together ...

Other materials:

Rear 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 rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation. Remove the rear brake rotor. Refer to R ...

Air Conditioning Evaporator Thermal Expansion Valve Replacement
Air Conditioning Evaporator Thermal Expansion Valve Replacement Callout Component Name Preliminary Procedure Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. Remove the air conditioning evaporator hos ...

Valve Guide Reaming, and Valve and Seat Grinding
Valve Cleaning Procedure Use soft bristle wire brush to clean any carbon build-up from the valve head. DO NOT use a wire brush on any part of the valve stem. The valve stem is chrome plated to provide enhanced wear characteristics. Wire brushing the stem could remove the chr ...

0.006