PONTIAC FIERO 1988 Service Repair Manual

AUTOMATIC TRANSMISSION 700-R4-1
AUTOMAT C TRANSM
CONTENTS
TRANSMISSION DISASSEMBLY
.............. General Service Information 700-R4-4
........................................... Disassembly 700-R4-4
2-4 Servo Assembly
................................. 700-R4-4
.................................. Servo Pin Length 700-R4-4
........................ Governor And Extension 700-R4-4
Valve Body And Wiring Harness
........... 700-R4-5
................ Transmission End Play Check 700-R4-6
Oil Pump Assembly
................................ 700-R4-7
2-4 Band. Reverse Input Clutch.
.................. Input And Input Gear Set 700-R4-8
Reaction Gear Set
................................. 700-R4- 10
.............. Lo And Reverse Clutch Parts 700-R4-10
COMPONENT REPAIR AND
TRANSMISSION ASSEMBLY
Inner Manual Linkage .......................... 700-R4- 10
........... Manual Shaft Seal Replacement 700-R4-10
Case
...................................................... 700-R4- 13
Third Accumulator Retainer And
Check Ball Assembly
........................ 700-R4- 15
Case Assembly
............................. ., ...... 700-R4- 18
Lo And Reverse Clutch Assembly
....... 700-R4- 18
*Lo and Reverse Clutch Backing
Plate Selection
.................................. 700-R4- 19
..................................... Parking Pawl 700-R4- 18
Reaction Internal Gear And
Carrier Assembly
.............................. 700-R4- 18
Reaction Internal Gear And Support
... 700-R4- 19
Lo And Reverse Support Assembly
..... 700-R4-20
Reaction Sun Gear And Shell
.............. 700-R4-21
Input Internal Gear And Output
.................. Shaft .......................... ... 700-R4-22
................ Input Carrier And Sun Gear 700-R4-24 *Input
Clutch Assembly
....................... 700-R4-25
Check Valve Retainer and Ball
Assembly Replacement Procedures
. . 700-R4-26
Forward Clutch Sprag Assembly
......... 700-R4-30
*3-4 Clutch Assembly
.......................... 700-R4-32
......... "3-4 Clutch Piston Travel Check 700-R4-32
Clutch Air Check
................................. 700-R4-33
......... *Reverse Input Clutch Assembly 700-R4-33
"Reverse Input Clutch
Backin~Plate
Selection ...................................... 700-R4-34
Reverse Input And Input Clutches
...... 700-R4-35
2-4 Band Assembly
.............................. 700-R4-35
*Oil Pump Assembly
............................ 700-R4-36
"Pump Body .......................................... 700-R4-36
Oil Pump Cover
.................................... 700-R4-36
Oil Pump Body And Cover
.................. 700-R4-39
Transmission End Play Check
.............. 700-R4-4 1
....... Valve Body And Associated Parts 700-R4-44
*Control Valve Assembly
..................... 700-R4-45
*2-4 Servo Assembly
............................. 700-R4-5 1
Governor Assembly ............................... 700-R4-52
........................................... Speedometer 700-R4-55
Torque Converter Assembly
................. 700-R4-55
SEALS AND BEARING
....................................... LOCATIONS 700-R4-58
TORQUE SPECIFICATIONS AND
.................. BUSH l NG LOCATIONS 700-R4-59
BUSHING REPLACEMENT
..................................... PROCEDURE 700-R4-60
GOVERNOR BORE REPAIR
PROCEDURE
......................... ............ 700-R4-63
...... ...................... SPECIAL TOOLS .. 700-R4-64
*Designates significant product changes
since the publication of the
1987 Service
Manual .

1 I Figure 67 Case and External Parts

AUTOMAT lC TRANSMISSION 700-R4-3
ILL. NO. DESCRIPTION
1 CONVERTER ASSEMBLY
2 SEAL ASSEMBLY, OIL
3 BUSHING, OIL PUMP BODY
4 BUSHING, STATOR SHAFT (FRONT)
5 BOLT, PUMP TO CASE
6 WASHER, PUMP TO CASE BOLT
7 PUMP ASSEMBLY, OIL
8 SEAL, OIL (PUMP TO CASE)
9 GASKET, PUMP COVER TO CASE
10 CASE, TRANSMISSION
11 VENT ASSEMBLY, TRANSMISSION
1 12 CONNECTOR, OIL COOLER PIPE 13 RING, SERVO COVER RETAINING
14 SEAL, "0" RlNG
(2-4 SERVO COVER)
15 COVER, 2-4 SERVO
16 PISTON, 4TH APPLY
17 RING, OIL SEAL
(4TH APPLY PISTON)
(OUTER)
18 RING, RETAINER (APPLY PIN)
19 WASHER, SERVO APPLY PIN
20 SPRING, SERVO APPLY PIN
21 SEAL,
"0" RlNG
22 HOUSING, SERVO PISTON (INNER)
23 RING, OIL SEAL
(2ND APPLY PISTON)
(INNER)
24 RING, OIL SEAL
(2ND APPLY PISTON)
(OUTER)
25 PISTON, 2ND APPLY
26 SPRING, SERVO CUSHION
27 RETAINER, SERVO CUSHION SPRING
28 RING, RETAINER
(2ND APPLY PISTON)
29 PIN, 2ND APPLY PISTON
31 SPRING, SERVO RETURN
32 PLUG, PRESSURE
33 CONNECTOR, ELECTRICAL
34 SEAL,
"0" RlNG (ELECTRICAL CONNECTION)
35 SEAL, CASE EXTENSION TO CASE
36 EXTENSION, CASE
37 BOLT, CASE EXTENSION TO
CASE 38 BUSHING, CASE EXTENSION
39 SEAL ASSEMBLY, CASE EXTENSION OIL
40 RETAINER, SPEEDO DRIVEN GEAR FITTING
41 BOLT
& WASHER ASSEMBLY
42 SEAL, "0" RlNG (SPEEDO FITTING TO
CASE EXTENSION)
43 FITTING ASSEMBLY, SPEEDO DRIVEN GEAR
44 GEAR, SPEEDO DRIVEN
45 GOVERNOR ASSEMBLY
46 COVER, GOVERNOR
47 SCREEN, TRANSMISSION OIL PRESSURE
(CONVERTER
81 GOVERNOR)
48 PIN, BAND ANCHOR
49 SEAL,
"0" RlNG (SOLENOID)
50 SOLENOID ASSEMBLY
51 BOLT, HEX WASHER HEAD (SOLENOID)
52 PISTON, 3-4 ACCUMULATOR
53 RING, OIL SEAL
(3-4 ACCUMULATOR PISTON)
54 SPRING, 3-4 ACCUMULATOR
55 BALL,
.25 DIAMETER 56 PLATE, VALVE BODY SPACER
ILL. NO. DESCRIPTION
59 SPRING, 1-2 ACCUMULATOR
60 RING, OIL SEAL (1
-2 ACCUMULATOR
PISTON)
61 PISTON, 1-2 ACCUMULATOR
62 COVER
& PIN ASSEMBLY, 1-2 ACCUM.
63 BOLT, ACCUMULATOR COVER
64 LINK, THROTTLE LEVER TO CABLE
65 LEVER
& BRACKET ASSEMBLY, THROTTLE
66 CLIP, ELECTRICAL WIRE
67 VALVE ASSEMBLY, CONTROL BODY
69 BOLT, VALVE BODY
70 SEAL, FILTER
71 FILTER ASSEMBLY, TRANSMISSION OIL
72 GASKET, TRANSMISSION OIL PAN
73 PAN, TRANSMISSION OIL
74 SCREW, SPEC. HEX WASHER HEAD (PAN)
75 BOLT, MANUAL DETENT SPRING
76 BUSHING, CASE
77 PIN, ACCUMULATOR PISTON
80 RETAINER
& BALL ASSEMBLY, 3RD
ACCUMULATOR
81 PLUG, TRANSMISSION CASE
(ACCUMULATOR BLEED)
82 PIN, GOVERNOR GEAR RETAINER
83 GEAR, GOVERNOR DRIVEN
84 PIN, GOVERNOR WEIGHT
85 CAP, GOVERNOR THRUST
86 PLUG, CASE SERVO
87 CLIP, FILTER RETAINER
88 GASKET, SPACER PLATE TO CASE
89 GASKET, SPACER PLATE TO VALVE BODY
90 BUSHING, STATOR SHAFT
(REAR)
91 BALL, CARBON STEEL (T.V. EXHAUST)
92 CONDUIT, SOLENOID WIRE
93 MAGNET, CHIP COLLECTOR
96 TUBE, AUXILIARY ACCUMULATOR VALVE
97 CLAMP, TUBE
98 NUT, FLANGED HEX
99 SPEED SENSOR, INTERNAL
TRANSMISSIOr 100 BOLT, SPEEDO SENSOR RETAINING
372 SWITCH, TEMPERATURE (SOME MODELS)
374 BOLT, SPECIAL HEX HEAD (M6 X
1 X 16)
375 BOLT, HEX HEAD (M6 X 1 X
35) 376 BOLT, HEX HEAD (M6 X 1 X 45)
377 AUXILIARY ACCUMULATOR VALVE
BODY ASSEMBLY
709 SPRING ASSEMBLY, MANUAL DETENT
Figure 68

700.R4.4 AUTOMATIC TRANSMISSION
TRANSMISSION DISASSEMBLY
General Service Information
e Teflon Oil Seal Rings
If any seal rings are damaged, cut, or do not
rotate freely in their groove be certain to check
the ring groove for debris, burrs, or damage.
s Thrust Washer Surfaces
The thrust washer and thrust bearing surfaces
may appear to be polished. This is a normal
condition and should not be considered damage.
Thoroughly clean the exterior of the
transmission.
Remove or Disconnect
e 'Torque Converter (1)
I I Figure 69 Holding Fixture
Install or Connect (Figure 69)
Tools Required:
J-8763-02 Holding Fixture and Base
1. 5-8763-02 onto the transmission case.
2. Holding fixture into the base.
Remove or Disconnect
e Drain the transmission fluid.
2-4 Servo Assembly
Remove or Disconnect (Figures 67,68, and 70)
TOOLS REQUIRED:
J-297 14 Servo Cover Compressor
1. Install J-29714.
2. Servo cover retaining ring (13)
3. Servo cover and
"0" ring seal (14 and 15)
4. 2-4 servo assembly (16-31)
Servo Pin Length
As a diagnostic aid, the servo pin length
should now be checked.
If the pin length is
too short
or too long be certain to inspect the
2-4 band and reverse input drum for damage
or wear when disassembled.
15 2-4 SERVO COVER
Figure 70 Servo Cover Removal
Remove or Disconnect (Figures 70, 71,72,73)
TOOLS REQUIRED:
5-22269-01 Piston Compressor
1. 4th apply piston (16)
2. Servo return spring (31)
3. Servo pin
retainer ring
(18), washer (19), and
apply pin spring (20)
4, 2nd apply piston
pin (29).
5. Install J-22269-01.
6. Retainer ring
(28)
7. Cushion spring
retainer (27) and cushion spring
(26)
Measure (Figure 74)
TOOLS REQUIRED:
5-33037 Band Apply Pin Tool
1. Install 5-33037 as shown with apply pin (29).
2. Apply
1 1 N . m
(100 in. lbs.) torque.
3. If white line "A" appears in gage slot "B" pin
length is correct.
4. Use pin selection chart to determine correct pin
length.
Governor and Extension
Remove or Disconnect (Figure 75)
1. Governor cover (46)
- tap around the cover flange with a punch to
remove
- DO NOT DAMAGE THE GOVERNOR
COVER
2. Governor assembly (45)
Mechanical Speedometer:
3. Bolt and washer assembly (41) and retainer (40)
4. Speedometer driven gear assembly (43), speedo
driven gear (44) and o-ring seal (42)
Internal Transmission Speed Sensor
(I. T. S.S.)
3. Speed sensor retaining bolt (100)
4. Speed
Sensor assembly
(99) and o-ring seal (42)

AUTOMA"PI&: TRANSMISSION 780-R4-5
5. Case extension bolts (37)
and case extension (36)
6. Extension seal ring (35)
7. Output
shaft sleeve (690) and output shaft o-ring
seal (691)
- Not all models use an output shaft sleeve
and seal
a Remove or Disconnect (Figures 75)
Models with Mechanical Speedometer
1. Speedometer drive gear
(689) and clip (688)
- push tab of retaining clip and tap
speedometer gear off the output shaft.
- use care not to damage the speedo gear
Valve Body and Wiring Harness
Remove or Disconnect (Figures 76, 77)
1. Screws (74), oil
pan (73), and gasket (72).
2. Oil filter
(71) and filter seal (70).
- Filter seal may be stuck in the case
3. Outside
electrical connector (33) and o-ring seal
(34).
4. Electrical connections from switches.
- refer to wiring diagrams in the Hydraulic
Diagnosis Section for specific model
applications
5. Solenoid bolts
(51) and solenoid assembly (50)
with o-ring seal (49) and wiring harness.
6. Accumulator cover bolts (63) and 1-2
accumulator cover and pin assembly (62).
7. 1-2 accumulator piston (61) and seal (60).
8. Spring (59).
Remove or Disconnect (Figures 78,99,88 and 81)
1. Bolt (75) and manual detent spring assembly
(709).
2. Electrical wire clips (66) and tube clamps (97).
3. Auxiliary valve tube (96).
4. Wiring harness retaining washer (A) and the
filter retainer clips
(87).
5. Bolts (69) and T.V. lever and bracket assembly
(65)
6. T.V. link (64)
Remove or Disconnect (Figures 78,88,8'1 and 82)
1. Remaining valve body bolts (69)
2. Manual valve link (705)
3. Control valve assembly (67)
4. Bolts
(374-376), auxiliary valve body (377), and
check
ball (55)
5. Spacer plate (56) and spacer plate gaskets (88 and
89)
6. Check balls (55 and 91) spring (54), piston (52),
sea1 (53) and pin
- Three checkballs are located under the
valve body, one in the auxiliary valve body
and four are located in the case. The large
copper flash colored ball is
# 10 check ball
(9 1)
ILL.
NO.
A
13 14
15 16
17
DESCBPlPT!ON
CASE SERVO BORE
RING,
SERVO COVER RETAINING
SEAL, "0" RING (2-4 SERVO COVER)
COVER, 2-4 SERVO
PISTON, 4TH APPLY
RING,
OIL SEAL (4TH APPLY PISTON) (OUTER)
18-30 2ND AP'PLY PISTON ASSEMBLY 21 SEAL, "0" RlNG
24 RING, OIL SEAL (2ND APPLY
PISTON)
(OUTER) 31 SPRING, SERVO RETURN JH0057-700R4
Figure 7 1 Servo Removal

700.R4-6 AUTOMATIC TRANSMISSION
ILL. NO. DESCRIPTION
13 RING, SERVO COVER RETAINING
14 SEAL, "0" RING (2-4
SERVO COVER)
15 COVER, 2-4 SERVO
16 PISTON, 4TH APPLY 17 RING, OIL SEAL (4TH APPLY PISTON)
(OUTER)
18 RING, RETAINER (APPLY PIN)
19 WASHER, SERVO APPLY PIN
20 SPRING, SERVO APPLY PIN
21 SEAL,
"0" RING 22 HOUSING, SERVO PISTON (INNER) 23 RING, OIL SEAL (2ND APPLY PISTON)
(INNER)
24 RING, OIL SEAL
(2ND APPLY PISTON)
(OUTER)
25 PISTON, 2ND APPLY
26 SPRING, SERVO CUSHION
27 RETAINER, SERVO CUSHION SPRING
28 RING, RETAINER
(2ND APPLY PISTON)
29 PIN, 2ND APPLY PISTON 31 SPRING, SERVO RETURN
JH0058-700R4
Figure 72 Servo Assembly Figure
73 Second
Servo Piston Retaining Ring
Removal
A. WHITE LINE B GAGE SLOT
PIN IS PRESET AT FACTORY AND MUST NOT BE
I I 2-4 SERVO PIN SELECTION I I
I I PIN LENGTH 1 PIN I.D. 11
Figure 74 Servo Pin Length
Transmission End Play Check
As a diagnostic aid transmission end play should
be checked prior to removing the internal parts. If the
end play is not within specifications you should watch
for possible worn or misassembled parts during
disassembly.
Tighten (Figures 84 and 85)
TOOLS REQUIRED:
J-24773-A Oil Pump Remover
5-25022-A End Play Adaptor (245 mm)
5-34725 End Play Adaptor (298 mm)
5-25025-7A Post
Dial Indicator
1. Remove an oil pump bolt (5) and install a 278 mm
(11 in.) bolt and locknut or J-25025-7A.

1 SOME MODELS 1 ILL.
NO. DESCRIPTION
10 CASE, TRANSMISSION
1 35 SEAL, CASE EXTENSION TO CASE
36 EXTENSION, CASE
37 BOLT,
CASE EXTENSION TO CASE
39 SEAL ASSEMBLY, CASE EXTENSION OIL
40 RETAINER, SPEEDO
DRIVEN GEAR FITTING
41 BOLT
& WASHER ASSEMBLY
42 SEAL,
"0" RlNG (SPEEDO FITTING TO
CASE EXTENSION)
43 FITTING ASSEMBLY, SPEEDO DRIVEN GEAI
44 GEAR, SPEEDO DRIVEN
45 GOVERNOR ASSEMBLY
46 COVER, GOVERNOR
99 SPEED SENSOR, INTERNAL
TRANSMISSIOI 100 BOLT, SPEEDO SENSOR RETAINING
687 SHAFT, OUTPUT
688 CLIP, SPEEDO DRIVE GEAR
689 GEAR, SPEEDO DRIVE
690 SLEEVE, OUTPUT SHAFT NOT USED ON
691 SEAL, OUTPUT SHAFT ALL MODELS
Figure 75 Extension and Associated Parts
2. Install J-25022-A or J-34725 as shown.
3. Install J-24773-A as shown.
4. Install dial indicator.
- set to zero
- pull up on J-24773-A
- end play should be 0.13/0.92 mm (.005/.
036 in.).
Oil Pump Assembly
Remove or Disconnect (Figures 88 and 89)
TOOLS REQUIRED:
J-24773-A Oil Pump Remover
1. "0" ring seal (6 18)
2.
All oil pump bolts (5) and washers (6)
3.
Oil pump assembly (7) with J-24773-A
4. Oil pump to case seal (8) and gasket (9)
AUTOMATIC TRANSMISSION 700-R4-7
ILL.
NO. DESCRIPTION
10 CASE, TRANSMISSION
33 CONNECTOR, ELECTRICAL
34 SEAL,
"0" RlNG (ELECTRICAL CONNECTION)
49 SEAL,
"0" RlNG (SOLENOID)
50 SOLENOID ASSEMBLY
51 BOLT, HEX WASHER HEAD (SOLENOID)
56 PLATE. VALVE BODY SPACER
/ 67 VALVE' ASSEMBLY, CONTROL BODY
70 SEAL, FILTER
1 71 FILTER ASSEMBLY, TRANSMISSION OIL
72 GASKET, TRANSMISSION OIL PAN
73 PAN, TRANSMISSION OIL
74 SCREW, SPEC. HEX WASHER HEAD (PAN)
87 CLIP, FILTER RETAINER
88 GASKET, SPACER PLATE TO CASE
89 GASKET, SPACER PLATE TO VALVE BODY
93 MAGNET, CHIP COLLECTOR
96 TUBE, AUXILIARY ACCUMULATOR VALVE
377 AUXILIARY ACCUMULATOR VALVE
BODY ASSEMBLY
Figure 76 Case and Attaching Parts
5. Reverse input clutch to oil pump thrust washer
(60 1)

700-R4-8 AUTOMATIC TRANSMISSION
DESCRIPTION
52 PISTON, 3-4 ACCUMULATOR
53 RING,
OIL SEAL (3-4 ACCUMULATOR PISTON)
54 SPRING, 3-4 ACCUMULATOR
56 PLATE, VALVE BODY SPACER
59 SPRING, 1-2 ACCUMULATOR (CONICAL) 60 RING, OIL SEAL (1-2 ACCUM. PISTON) 61 PISTON, 1-2 ACCUMULATOR
Figure 77 Accumulator Assembly
A WASHER WlRE RETAINER
50 SOLENOID ASSEMBLY
51 BOLT, HEX WASHER HEAD (SOLENOID)
63 BOLT, ACCUMULATOR COVER
66 CLIP, ELECTRICAL WlRE
69 BOLT, VALVE BODY
75 BOLT, MANUAL DETENT SPRING
87 CLIP, FILTER RETAINER
92 CONDUIT, SOLENOID WlRE
374 BOLT, SPEC. HEX WASHER HEAD
(M6
X 1 X 18)
375 BOLT, HEX HEAD (M6 X 1 X 35) 376 BOLT, HEX HEAD (M6 X 1 X 45) JH0064-700-R4
Figure 78 Valve Body Bolt Locations 64
LINK, THROTTLE LEVER
TO CABLE
65 LEVER & BRACKET ASSEMBLY, THROTTLE
69 BOLTS, CONTROL VALVE
ASSEMBLY
JH0065-700R4
Figure 79 T.V. Lever and Bracket
MANUAL VALVE
INNER DETENT LEVER
MANUAL VALVE
LINK MANUAL DETENT
SPRING ASSEMBLY JHOO66-7OOR4
Figure 80 Manual Valve Link
2-4 Band Reverse input Clutch, lnput Clutch and
lnput Gear Set (Figures
88,89 and 90)
1. Reverse input clutch (605) and input clutch (62)
together
- (grasp the turbine shaft and lift)
2. Band assembly pin (48)
3. The 2-4 band assembly (602)
4. Input sun gear (658)
Install or Connect (Figure 91)
TOOLS REQUIRED:
J-29837 Output Shaft Support Fixture
e J-29837 as shown
Important
e Output shaft (687) may fall free when input
carrier retaining ring (661) is removed if
J-2983'7 is not used.

AUTOMATIC TRANSMISSION 700-R4-9
NO. DESCRIPTION
A WASHER, WIRE RETAINING
33 CONNECTOR, ELECTRICAL
96 TUBE, AUXILIARY ACCUMULATOR VALVE
97 CLAMP, TUBE
374 BOLT, SPECIAL HEX HEAD (M6 X 1 X 16)
375 BOLT, HEX HEAD (M6 X
1 X 35) 376 BOLT, HEX HEAD (M6 X 1 X 45) 377 AUXILIARY ACCUM. VALVE BODY ASM.
71 0 BRACKET, PARKING LOCK
71 5 BOLT, PARKING LOCK BRACKET
JH0067-700R4
Figure 8 1 Removing Auxiliary Valve Body Assembly
55A #2 CHECKBALL (3RD CLUTCH ACCUM.) 558 #I 2 CHECKBALL (FORWARD CLUTCH)
55C #6 CHECKBALL (DRIVE 3) 9 1 #I 0 CHECKBALL (T.V. EXHAUST)
359 CUP PLUG - ORIFICE
ILL.
NO. DESCRlPTlON
47A GOVERNOR FILTER LOCATION
478 CONVERTER CLUTCH FILTER LOCATION
55E #4 CHECK BALL (3-4 CLUTCHl3-2 EX.)
55F
#8 CHECK BALL (2NDl1-2) 55G #I CHECK BALL (4TH ACCUMULATOR)
55H
#3 CHECK BALL (PART THROTTLEIDRIVE 3) 106 RETAINER & BALL ASM. (DOUBLE ORIFICE)
JH0069-700R4-R1
Figure 83 Case Checkballs and Filters
A 298mm TURBINE SHAFT
B 245mm TURBINE SHAFT
Figure
82 Valve Body Checkballs Figure 84 End
Play Tool