1988 PONTIAC FIERO Service Repair Manual

78-16 BSPEED 77MM TMNSMISSION
49. O-RING 67. TRANSMISSION
50. BEARING CASE
Figure 37 Front Countershaft Bearing Assembly
Figure
38 Front Countershaft Bearing Installation
DRIVE GEAR
Assemble
1. Using Tool J 22912-01 (between clutch teeth
and gear teeth), Tool
J 6133-A and an arbor
press, install bearing on drive gear.
2. Coat roller bearings and drive gear bearing bore
with light weight grease.
3. Roller bearings into bore of drive gear.
4. Thrust bearing and race in drive gear.
MAINSHAm
NOTICE: If replacing firstfsecond or thirdlfourth
synchronizer blocking rings, soak new blocker
ring assemblies for 10 minutes in Dexron
I1 or
equivalent before assembly on mainshaft.
Assemble
1. Coat mainshaft and
gear bores with transmission
lubricant.
2. Anti-rattle
spring and ball in hub.
3. Slide first-second synchronizer sleeve on
mainshaft hub aligning marks made at
disassembly.
4. First-second synchronizer keys and springs.
Engage tang end of each spring in same syn-
chronizer key but position open end of springs
opposite of each other (Figure 39).
NOTICE: Use care in synchronizer spring place-
ment. Synchronizer can be assembled with
improper spring placement, but hard shifting will
result.
Figure 39 Synchronizer Spring Installation
5. Three-piece first gear blocker ring assembly.
6. Drop locating pin into mainshaft.
7. Slide sleeve and bearing onto mainshaft, align-
ing notch in sleeve with locating pin.
8. First gear, aligning slots in first gear with tabs
on blocker ring assembly.
9. Rear
mainshaft bearing with taper facing rear of
shaft.
10. Lubricate fifth gear splines with petroleum jelly.
1 1. Position fifth gear on mainshaft.
12. Using a press and Tool
J 25234, press fifth gear
onto mainshaft.
NOTICE: Carefully align the mainshaft and gear
splines. If splines are improperly aligned, dam-
age could occur when the gear is pressed onto the
mainshaft.
13. Fifth gear snap ring.
14. Three-piece
second gear blocker ring assembly
and thrust washer (Figure 24).

15. Spiral snap ring,
using Tool J 37360.
16. Second gear spacer, needle bearing and gear,
aligning slots in second gear with tabs on
blocker ring assembly.
17. Second gear thrust washer and
snap ring.
18. Third
gear, spacer and needle bearing assembly.
Make sure the bearing spacer is not trapped
between the gear face and snap ring. The spacer
runs inside the gear bore.
19. Using
a press and Tool
J 37372, install
thirdtfourth synchronizer, third blocker ring and
third gear as an assembly.
Important
Before pressing components together, make
sure the synchronizer hub faces the short end of
the mainshaft. Hold third gear against the syn-
chronizer to maintain blocker ring alignment
with keys.
Assemble
1. Using a press and Bearing Installation Tools
J 37357 and J 8092 or equivalent, install front
countershaft bearing onto countershaft.
2. Position countershaft in case.
3. Using
a press and Bearing Installation Tool
J 37372 or equivalent, install countershaft rear
bearing to countershaft (Figure 40).
Figure 40 Rear Countershaft Bearing Installation
Support the countershaft with Tool J 37357 or
equivalent.
NOTICE: Failure to properly support the coun-
tershaft may result in permanent distortion of the
case during bearing installation. 4.
Rear countershaft bearing race.
5. Position rubber O-ring and reverse idler gear in
case with shift lever groove facing rear of case.
6. Reverse idler shaft from rear of case.
7. Install roll pin in idler shaft.
8. Install countershaft retainer (without shims) to
transmission housing.
Tighten
@ Torque bolts to 20 Wm (15 lbs. ft.)
Measure
@ Countershaft end play using dial indicator
J 8001. (Figure 41)
Figure 41 Countershaft End Play Measurement
9. Remove
retainer and install shim(s) as necessary
to provide proper end play. Zero end play with
no preload is ideal, but up to
.004 in.(. l0rnrn)
end play is allowable. Do not preload bearing
with
shim(s) larger than original end play mea-
surement. Reinstall retainer, re-torque and bend
tabs over the four attaching bolts.
10. Position reverse shift fork in case.
11. Assembled mainshaft
in transmission case.
12. Rear
mainshaft bearing race in case.
13. Drive gear
in case (make sure rollers, thrust
bearing and washer are in place), and engage in
third-fourth synchronizer sleeve and blocker
ring.
-
14. Front bearing race in
front bearing retainer. Do
not install shims in front bearing retainer at this
time.
15. Temporarily install front bearing retainer.
16. Fifth gear on countershaft. Slide shift railtfifth
gear shift fork assembly into case. As shift rail
enters case, align reverse shift fork and slide rail
through fork. Position lever return spring in case
with long end of spring to rear, and slide rail
through spring (Figure 13).

78-18 5-SPEED 77MM TRANSMISSION
Blocker ring and fifth gear synchronizer in fifth
gear shift fork. Slide fork rail assembly and syn-
chronizer into position. (Figure 20)
Fifth gear synchronizer retainer and snap ring
(Figure 12).
Oiling funnel into rear of countershaft (Figure
9)
Position fifthlreverse shift lever in case.
Connect lever return spring to front of case.
Make sure reverse shift fork pin and fifth gear
shift rail pin are engaged with shift lever and
install fifth
gearlreverse lever, pivot bolt and
retaining clip. Coat pivot bolt threads with pipe
thread sealant
#lo52080 or equivalent.
Reverse lamp switch. Coat threads with pipe
thread sealant
# 1052080 or equivalent.
Speedometer gear and retaining clip.
Circlip.
Apply 3mm
(118in.) bead of RTV Sealant,
# 105275 1 or equivalent, to transmission cover
assembly.
Make sure all synchronizers are in the neutral
position and that the shift forks in the cover are
in the neutral (center) position. Lower cover
onto case while aligning shift forks and synchro-
nizer sleeves.
Center cover and install two dowel bolts.
Remaining cover bolts.
Tighten
@ Torque all cover bolts to 14 N*m (10 lbs.
ft.).
Apply 3mm (118 in.) bead of RTV Sealant,
#I05275 1 or equivalent, to extension housing
mating surface.
Coat detent spring with petroleum jelly and
insert in offset lever. Lubricate detent plate and
install detent ball in neutral position on plate.
Position offset lever in extension housing with
spring over detent ball. Slide lever and exten-
sion housing into position as an assembly.
Extension housing vent.
Press downward on offset lever to compress
detent spring and push lever and housing into
position.
Extension housing bolts. Apply pipe thread
sealant
#lo52080 or equivalent to threads of
top two bolts.
Tighten
@ Torque extension housing bolts to 30 Nm
(23 lbs. ft.)
Align and install roll pin in offset lever and shift
rail. 35. Damper
sleeve in offset lever.
36. Turn transmission case on end, and mount a dial
indicator on extension housing with indicator on
the end of mainshaft (Figure 42).
Figure 42 Measuring End Play
Measure
@ Rotate mainshaft and zero dial indicator.
Pull upward on mainshaft until end play is
removed and record reading.
@ Ideal mainshaft end play is zero, with plus
or minus
.001in. (.03mm) allowable. To
set preload, select a shim pack equal to
the dial indicator reading recorded.
37. Remove
front bearing retainer and front bearing
race.
38. Install
necessary shims and reinstall bearing
race.
39. Apply
a 3mm diameter
(118 inch) bead of RTV
sealant,
#lo5275 1 or equivalent, on case mat-
ing surface of front bearing retainer.
40. Bearing retainer with narrow
or smaller notch
facing upward.
NOICE: Sealer must not cover notch in bearing
retainer.
Tighten
@ Torque attaching bolts to 20 N*m (15 lbs.
ft.).
41. Fill transmission to its proper level with
Dexron
I1 #I05 1855
or equivalent. Apply pipe thread
sealant
#lo52080 or equivalent to threads of
drainlfill plugs before installation.

TRANSMISSION TO ENGINE 75 Nm 55 LBS. FT.
EXTENSION HOUSING TO CASE 30 N.rn 25 LBS. FT.
TRANSMISSION COVER TO CASE
14 N-rn 10 LBS. FT.
FRONT BEARING RETAINER TO CASE 20
Nm 15 LBS. FT.
COUNTERSHAFT RETAINER TO CASE
20 N.m 15 LBS. FT.
REVERSE PIVOT BOLT TO CASE 27
N.m 20 LBS. FT.
FILL PLUG TO CASE 27 N.m 20 LBS. FT.
CROSSMEMBER TO FRAME 50
N.m 35 LBS. FT.
TRANSMISSION MOUNT TO TRANSMISSION 50
N.m 35 LBS. FT.
TRANSMISSION MOUNT TO CROSSMEMBER 50
Nm 35 LBS. FT.
LUBE CAPACITY (APPROXIMATELY)
2.8 LITRES
LUBE RECOMMENDED DEXRON 11 #I051855 OR
EQUIVALENT
MAINSHAR END PLAY SHIMS COUNTERSHAFT
END PLAY SHIMS (Thickness in Inches) (Thickness
in Inches)
Figure 43 Specifications

1. J 8001 DIAL INDICATOR
8. J 36842 OR J34162 2. J 8092 DRIVER HANDLE HOLDING FIXTURE
3. J 21426 EXTENSION HOUSING 9.
J 6133-A
BEARING INSTALLER
SEAL INSTALLER 10. J 8433 UNIVERSAL PULLER BAR
4. J 22912-01 BEARING PULLER
11.
J 37372 BEARING INSTALLER
5. J 23062-14 EXTENSION HOUSING
12. J 26900-13
DIAL INDICATOR STAND
BUSHING INSTALLER
13. J 37358 BEARING REMOVER
14.
J 37359 BEARING REMOVER
15. J 37360 SNAP
RING TOOL
Figure 44 Special Tools

CLUTCH 7C-4
SECTION 76
CLUTCH
CONTENTS
GENERAL DESCRIPTION .......................... .. ............................................................. 7C-I
DIAGNOSIS ...................................................................................................................... 7C-3
Preliminary Checks ....................... ... ............................................................................ 7C-2
Bleeding Hydraulic Clutch System ................... .. .......................................................... 7C-2
ON-VEHICLE SERVICE ................................................................................................. 7C-5
Clutch Hydraulic System ................................................................................................. 7C-5
..................... Pressure Plate and Disc .. ........................................................................... 7C-6
Clutch Pedal ..................................................................................................................... 7C-6
Pilot Bearing .................................................................................................................. 7C-6
....................................................................................................... SPECIFICATIONS 7C-8
............................................................................................................ SPECIAL TOOLS 7C-8
GENERAL DESCRIPTION
COMPONENTS
The principal parts of a clutch system are: the
driving member and the operating members. Figure
7C-1 shows an exploded view of the clutch system.
DRIVEN MEMBERS (FIGURES 7C-1 AND 7C-2)
The driven member is the clutch disc with a
splined hub which is free to slide lengthwise along the
splines of the input shaft, but which drives the input
shaft through these same splines.
The driving and driven members are held in
contact by spring pressure. This pressure is exerted by
a diaphragm spring in the pressure plate assembly.
HYDRAULIC CLUTCH (FIGURE 7C-3)
A hydraulic clutch operating mechanism is used
on all models. The
mechanism consist of a remote
reservoir, clutch master cylinder and slave cylinder.
The remote reservoir is mounted to a bracket which
bolts to the power brake booster. The clutch master
cylinder is mounted on the cowl panel and the slave
cylinder is mounted on the bell housing. The clutch
master cylinder is operated directly off the clutch
pedal.
When the clutch pedal is pressed down, hydraulic
fluid under pressure from the clutch master cylinder
flows into the slave cylinder. Since the piston is also
connected to the clutch fork this lever moves the
release bearing into contact with the clutch cover
release fingers to disengage the clutch. The hydraulic
clutch system locates the clutch pedal height and
provides automatic clutch adjustment. No adjustment
of clutch linkage or pedal position is required.
OPERATING MEMBERS (FIGURE 7C-3)
HYDRAULIC CLUTCH FLUID
When adding fluid to or refilling the system after
The clutch release system is operated by service operations use GM Delco Supreme No. 11 hydraulic pressure and consists of the clutch pedal, brake fluid or an equivalent fluid that meets DOT 3 clutch master cylinder, clutch slave cylinder, clutch specifications. fork and clutch release bearing.
NOTICE: Do not use mineral or paraffin base oil in
the Clutch Hydraulic System. These fluids will
damage the rubber parts in the cylinders.

7C-2 CLUTCH
PRELIMINARY CHECKS
Before attempting to repair the clutch,
transmission or related hydraulic components for any
reason other than
an obvious failure, the problem and
probable cause should be identified.
A large percentage
of clutch and manual transmission
problenls are
manifested by shifting difficulties such as high shift
effort, gear clash and grinding or transmission
blockout. When any of these problems occur, a careful
analysis of these difficulties should be accomplished
and the following checks and adjustments performed
in the presented sequence before removing the clutch
or transmission for repairs.
Before
removal of the clutch hydraulic system,
verify the malfunction by renloving the clutch housing
dust shield and
measure the travel of the clutch slave
cylinder push rod. With clutch pedal pushed fully to
the floor, the
slave cylinder push rod should extend
14.53mm (0.57 inch) minimum against the clutch
release lever. Do
not replace the hydraulic system if
push rod travel exceeds this distance.
If slave cylinder does not meet the travel require-
ments, check the reservoir fluid level. The slave cylinder
must be in place when checking the fluid level. The proper
level is indicated by a step on the reservoir. Fill to the
specified level with
GM Delco Supreme No. 11 Brake
Fluid or an equivalent fluid that meets DOT
3 specifica-
tions. Do not overfill. The upper portion of the reservoir
must accept fluid that is displaced from the slave cylinder
as the clutch wears.
NOTICE: Carefully clean the top and sides of the
reservoir before opening to prevent contamination of
the system with dirt, water or other foreign material.
Remove the reservoir diaphragm before adding fluid.
Carefully replace the diaphragm, cover gasket and
cover after filling.
If the reservoir requires any fluid, check the
hydraulic system components for leakage. Remove the
rubber boots from the cylinder and check for leakage
past the pistons. A slight wetting of the surfaces is
acceptable. Replace the system, if excessive leakage is
evident.
BLEEDING CLUTCH SYSTEM
allowed to fall so low that air has been drawn into the
master cylinder.
NOTICE: Never, under any circumstances, use
fluid which has been bled from a system to fill the
reservoir as it may be aerated, have too much
moisture content and possibly be contaminated.
Clean dirt and grease from the cap to ensure no
foreign substances enter the system.
Remove cap and diaphragm and
fill reservoir to
the top with approved brake fluid only. (Brake
fluid must be certified to DOT 3 specifications).
Fully loosen bleed screw which is in the slave
cylinder body next to the inlet connection.
Fluid will now begin to move from the master
cylinder down the tube to the slave. It is
important that for efficient gravity
fill, the
reservoir must be kept full at all times.
It will be noticeable at this point that bubbles will
appear at the bleed screw outlet. This means that
air is being expelled. When the slave is full, a
steady stream of fluid will come from the slave
outlet. At this point tighten bleed screw to a
torque of 2
N .m.
Assemble diaphragm and cap to the reservoir,
fluid in reservoir should be level with step.
Exert a light load (approximately 20 lbs.) to the
slave cylinder piston by pushing release lever
towards the cylinder and loosen bleed screw.
Maintain a constant light load, fluid and any air
that is left will be expelled through the bleed port.
Tighten bleed screw when a steady flow of fluid
and no air is being expelled.
Renew fluid level in reservoir, assemble
diaphragm and cap. If necessary, repeat Steps
7
and 8.
Exert light load to release lever as in Step 7 (do
not open bleed screw), piston in slave will move
slowly down bore. Repeat 2-3 times, fluid
n~oven~ent will force any air left in the system into
the reservoir.
The hydraulic system should now be fully bled
and should release the clutch. Check vehicle by
starting, pushing clutch pedal to the floor and
selecting reverse gear. There should be no grating
of gears, if there is, the hydraulic system could
still contain air. If this is the case, repeat bleed
The process of removing air from the
line and procedure.
cylinders is known as "bleeding" and is necessary Check push rod travel at the
slave cylinder to insure
whenever the level of fluid in the reservoir has been the minimum travel
of
14.53mm (0.57 inch) for V-8
and 1 lrnm (0.43 inch) for V-6.

CLUTCH 7C-3
FLYWHEEL DRIVEN PLATE ASM
. . . - - - - . . - . . ---AND COVER
PRESSORE PLATE
! ASM
LUTCH RELEASE BEARING
CLUTCH FORK CLUTCH HOUSING
CLUTCH FORK
BALL STUD
I I Figure 7C-1 Exploded View of Clutch System
BENT FINGER
5. Pressure Plate 7. Cover
Figure 7C-2 Cross-Section of Clutch Assembly