1988 PONTIAC FIERO Service Repair Manual

76. SPRING CLIP JIOOO~-7~-F
Figure 11 Reverse Lever Retaining Clip
63. RETAINER
64. SNAP RING
Figure 12 Fifth Gear Synchronizer
15. Fifth
gear, synchronizer, shift fork and shift rail
as an assembly. If necessary, rotate rail to disen-
gage from reverse lever assembly (Figure 14).
Figure 14 Fifth Gear Synchronizer (Removal and
Installation)
16. Snap ring, speedometer gear and retaining clip.
17. Remove
snap ring from fifth speed driven gear
(Figure 15).
Figure 15 Fifth Gear Snap Ring
18. Front bearing retainer bolts.
19. Front bearing retainer.
20. Front bearing race and end play shims from
front bearing retainer (Figure 16).
21. Rotate drive gear until
flat surface faces
coun-
tershaft and remove drive gear from transmis-
sion case. Be careful not to drop the 15 roller
bearings, thrust bearing, or race from rear of
drive gear (Figure 17).
22. Fourth
gear blocker ring from
thirdlfourth
synchronizer.
23. Mainshaft rear bearing race. If race sticks, it is
probably misaligned in the case bore. To free
the race, work the shaft back and forth in the
Figure 13 Reverse Lock Spring case.

BEARING RETAINER
Figure 16 Bearing Retainer and Shims Figure 18 Mainshaft
(Removal and Installation)
Figure
17 Drive Gear (Removal and Installation)
Tilt mainshaft upward and remove assembly
from transmission case (Figure 18).
Reverse fork assembly from transmission case.
Countershaft retainer and shims (Figure 19).
Using hammer and punch, drive roll pin from
forward end of reverse idler shaft and remove
reverse idler shaft, rubber O-ring and gear from
the transmission case (Figure 20).
Rear countershaft bearing race.
Countershaft bearing using appropriate pullers (Figure 21).
Move countershaft assembly rearward, tilt
countershaft upward and remove from case.
Rear countershaft bearing from shaft using tool
J 37359 with J 22912-01.
55. COUNTERSHAFT
Figure 19 Countershaft Retainer
71. ROLL PIN
Figure 20 Reverse Idler Gear Shaft

Figure 21 Countershaft Bearing Removal
Disassemble
I. Thrust bearing washer from front end of
mainshaft.
2. Scribe reference
mark on third-fourth synchro-
nizer hub and sleeve for reassembly.
3. Remove third-fourth synchronizer blocker ring, Figure 22 Third-Fourth Synchronizer Removal
sleeve, hub and third gear as an assembly from
mainshaft (Figure
22).
4. Needle bearing assembly and spacer (Figure
23).
5. Second gear snap ring and thrust washer.
6. Second gear, spacer and needle bearing.
7. Spiral snap ring.
8. Thrust washer.
9. Three-piece second gear blocker ring assembly.
10. Scribe reference mark on first-second synchro-
nizer hub and sleeve for reassembly.
1 I. Synchronizer spring and keys from first-reverse
sliding gear.
12. Sleeve from mainshaft hub.
13. Anti-rattle spring and ball from hub.
NOTICE: Do not attempt to remove the first-
second-reverse hub from mainshaft. The hub and
shaft are permanently assembled and machined as
a matched set.
14. MAINSHAFT
36. NEEDLE BEARING
37. SPACER
Figure 23 Needle Bearing Removal

5-SPEED 77MM TRANSMISSION 78-9 1
14. Fifth gear, using J 22912-01 and press.
15. Rear bearing.
16. First gear.
17. Needle bearing and sleeve.
18. Locating pin.
19. Three-piece first gear blocker ring assembly
(Figure
24).
17, INNER CONE
18. OUTER CONE
19. BLOCKER RING J10019-78-F
Figure 24 Three-piece Blocker Ring
DRIVE GEAR
Disassemble
1. Bearing race.
2. Thrust bearing.
3. Roller bearings from cavity of drive gear (Fig-
ure
25).
29. THRUST BEARING
30. THRUST RACE
98. ROLLER BEARINGS
J10020-78-F
4. Using Tool J 229 12-01 and arbor press, remove
bearing from drive gear (Figure
26).
-
Figure 26 Drive Gear Bearing Removal
Clean
@ Parts in appropriate solvent.
Gear teeth and drive shaft pilot for wear.
GLEANING AND INSPECnION
Transmission Case
Clean
1. Transmission case thoroughly inside and
outside with appropriate solvent.
2. Magnetic disk at bottom of transmission
case.
1. Case for cracks.
2. Front and rear faces of the transmission
case for burrs, and if present, dress them
off with a fine mill file.
Bearing Rollers and Spacers
The following should be inspected and
replaced if worn:
@ dkve gear bearing rollers
@ reverse idler shaft
@ spacers Figure 25 Drive Gear

Gears .
t, Drive gear bearing rollers for chips,
cracks, or excessive wear and replace if
necessary.
@ Clutch sleeves to insure that they slide
freely on their hubs.
Front and Rear Bearings
Clean
t, Front and rear bearings thoroughly with
appropriate solvent.
1. Blow out bearings with compressed air.
NOTICE: Do not allow the bearings to spin.
Turn them slowly by hana. Spinning bearings
may damage the race and rollers.
2. Lubricate bearings with transmission lubricant.
@ Bearings for roughness by slowly turning
race by hand.
Synchronizer Blocking Rings
Firsthecond and thirdlfourth blocker rings are
lined with friction material and cannot be checked
visually for wear. Replacement is necessary when gap
between blocker teeth and adjacent clutch teeth is sig-
nificantly less than specified. Fifth gear blocker ring
is brass and can be checked visually for wear or
damage.
ThirdIFouHh Blocker Rings
Assemble
1. Third gear blocker ring to third gear with twist-
ing motion to fully seat.
2. Fourth gear blocker ring to main drive gear with
twisting motion to fully seat.
Measure
Gap between vertical faces of blocker teeth and
clutch teeth. Nominal gap is
.035 -.059 inches
(.88 - 1.5mm) for new blocker rings (Figure
30).
FirsvSecond Blocker Rings
Assemble
1. Three-piece first gear blocker ring assembly
with twisting motion to fully seat. 2.
Three-piece first gear
blocker ring assembly,
with needle bearing and bearing sleeve, to first
gear.
3. Three-piece second gear blocker ring assembly with twisting motion to fully seat.
4. Three-piece second gear blocker ring assembly,
with thrust washer, to second gear.
Measure
Gap between vertical faces of blocker teeth and
clutch teeth. Nominal gap is ,032
-.056 inches
(.81 -1.4mm) for new blocker ring assemblies
(Figure 30).
Synchronizer Keys and Springs
Figures 27,28,29
NOTICE: The synchronizer hubs and sliding
sleeves are a selected assembly and should be
kept together as originally assembled, but the
keys and springs may be replaced if worn or
broken.
Remove or Disconnect
1. If
relation of hub and sleeve are not already
marked, mark for assembly purposes.
2.
Push the sliding sleeve from the hub, the keys
will fall free and the springs may be easily
removed.
Install or Connect
1. Place a blocker ring on side of the hub and
sleeve and install keys and retain with a spring.
2. Place blocker ring on opposite side of hub and
sleeve and install remaining spring.
15. SPRING 32. HUB 34. SLEEVE
31. BLOCKER RING 33. KEYS
J 10022-78-F
Figure 27 Third-Fourth Synchronizer Assembly

14. MAINSHAFT WITH HUB
15. SPRING
16. REVERSE SLIDING GEAR
17, INNER CONE
18. OUTER CONE
19. BLOCKER RING
33. KEYS
47.
ANIT-RAlTLE BALL
48. ANTI-RATTLE SPRING
Figure 28 First-Second Synchronizer Assembly
63. RETAINER
Figure 29 Fifth Gear Synchronizer Assembly
Extension Housing Oil Seal
Figure 31
Remove or Disconnect
1. Pry oil seal
out of extension housing, using a
screwdriver or small chisel.
Install or Connect
1. New oil seal into extension housing using Tool
J 21426.
2. Lubricate
I.D. of seal with transmission
lubricant.
Extension Housing Bushing
A. BLOCKER TEETH
B. FEELER GAGE
C. CLUTCH TEETH
Figure 32
rn Remove or Disconned
1. Pry oil seal out of extension housing, using a
screwdriver or small chisel.
2. Drive the bushing
out of housing, using Tool
J 8092 with J 23062-14.
Install or Connect
1. Bushing in housing, using Tool J 8092 with
J 23062-14.
2. New
oil seal into extension housing using
Tm1
J 21426.
3. Lubricate
I.D. of seal with transmission
Figure 30 Blocker Ring Wear Gap Measurement lubricant.

Figure 31 Extension Housing Seal
Figure
32 Extension Housing Bushing
Drive Gear Bearing Retainer Oil Seal
Figure 33
Remove or Disconnect
1. Pry oil seal out, using a screwdriver or small
chisel.
Install or Connect
1. New seal into retainer using Tool J 23096 until
it bottoms in bore.
2. Lubricate I.D. of seal with transmission
lubricant.
Figure 33 Bearing Retainer Oil Seal Installation
Transmission Cover
Figure 34
Disassemble
1. Place selector am plates and shift rail in neutral
position (centered).
1. TRANSMISSION COVER 8. SELECTOR ARM
2. ALIGNMENT BOLT
9. INTERLOCK PLATE
3. 13
Nm (10 LBS. FT.) 10. 1STI2ND SHlFT
FORK
11. INSERT
5. SHIFT RAIL PLUG 12. SHIFT FORK PLATE
6. SHIFT RAIL 13. ROLL PIN
7. 3RDl4TH SHlFT FORK
Figure 34 Transmission Cover

5-SPEED 77MM TRANSMISSION 78-15
2. Rotate shift rail until selector arm disengages
from selector arm plates and roll pin is
accessible.
3. Selector arm roll pin using a pin punch and ham-
mer (Figure
35).
Figure 35 Selector Arm (Removal and Installation)
4. Shift rail, shift forks, selector arm plates, selec-
tor arm, interlock plate and roll pin.
5. Transmission cover to extension housing O-ring
seal using a screwdriver.
6. Nylon inserts and selector arm plates from shift
forks. Note position of inserts and plates for
assembly reference.
Assemble
1. Nylon inserts and selector arm plates in shift
forks.
2. If removed, Coat edges of shift rail plug with
sealer
#lo52624 or equivalent before installing.
3. Coat shift rail and rail bores with transmission
lubricant.
4. Shift rail in cover until flush with inside edge of
cover.
5. Place first-second shift fork in cover with fork
offset facing rear of cover and push shift rail
through fork. The first-second shift fork is the
larger of the two forks.
-
6. Position selector arm and C-shaped interlock
plate in cover and insert shift rail through
arm.
Widest part of interlock plate must face away
from cover, and selector
arm roll pin hole must
face downward and toward rear of cover.
'7. Position third-fourth shift fork in cover with
fork offset facing rear of cover. Third-fourth
shift fork selector
arm plate must be under first-
second shift fork selector
arm plate,
8. Push shift rail through third-fourth shift fork and
into front bore in cover.
9. Rotate shift rail until selector arm plate at for-
ward end of rail faces away from, but is parallel
to cover.
10. Align roll pin holes in selector arm and shift rail
and install roll pin. Roll pin must be flush with
surface of selector
arm to prevent pin from con-
tacting selector
arm plates during shifts.
11. New transmission cover to extension housing O-
ring seal.
12. Coat O-ring seal with transmission lubricant.
Front Countersha& Bearing
Remove or Disconnect
NOTICE: Remove the front countershaft bearing
race only if it is worn or damaged.
1. Using a press and Bearing Remover J 8092 with
Bearing Receiver and case support
J 37358 or
equivalent, remove bearing race and O-ring
from case (Figure
36). '
NOTICE: Failure to support the case properly
will result in permanent distortion of the case
during bearing race removal.
Figure 36 Front Countershaft Bearing Removal
Install or Connect
1. New O-ring onto bearing race and lubricate with
petroleum jelly.
2. Position bearing race in case (Figure 37).
3. Keeping race square with case bore, install race
with hand pressure until O-ring is below edge of
case.
4. Support transmission case on press, and using
Bearing Installation Tool
J 37357 and
Remover/Installer J 8092 or equivalent press
bearing race until flush with case (Figure
38).