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:

Dinghy Towing RS Model with Automatic Transmission
Caution If the vehicle is towed with all four wheels on the ground, the drivetrain components could be damaged. The repairs would not be covered by the vehicle warranty. Do not tow the vehicle with all four wheels on the ground. The vehicle was not designed to be towed with all four wheels o ...

Tire Terminology and Definitions
Air Pressure The amount of air inside the tire pressing outward on each square inch of the tire. Air pressure is expressed in kPa (kilopascal) or psi (pounds per square inch). Accessory Weight The combined weight of optional accessories. Some examples of optional access ...

Camshaft Installation
Special Tools EN-422 Installer For equivalent regional tools, refer to Special Tools. Note: Coat with MoS 2 lubricating paste. Refer to Adhesives, Fluids, Lubricants, and Sealers. Install the intake camshaft (1). Note: Note the identification mark ...

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