PONTIAC FIERO 1988 Service Repair Manual

700-R4-20 AUTOMATIC f RANSMlSSlON
ILL. NO. DESCRIPTION
10 CASE, TRANSMISSION
681 CARRIER ASSEMBLY, REACTION
682 PLATE ASSEMBLY, LO
& REVERSE CLUTCH
682A PLATE, LO
& REVERSE CLUTCH (WAVED) 6828 PLATE, LO & REVERSE CL. (SELECTIVE)
683 BEARING ASSEMBLY, 'THRUST (REACTION
CARRIERISUPPORT) 684 GEAR, INTERNAL REACTION
685 SUPPORT, INTERNAL REACTION GEAR
692 BRG., REACTION GEAR SUPPORT TO CASE
697 DEFLECTOR, OIL (HIGH OUTPUT
MODELS ONLY)
Figure
105 Reaction Internal Gear and Carrier Assembly Installation
ILL.
NO. DESCRIPTION
10 CASE, TRANSMISSION
681 CARRlER ASSEMBLY, REACTION 683 BEARING ASSEMBLY, THRUST (REACTION
CARR I
ER/SUPPORT) 685 SUPPORT, INTERNAL REACTION GEAR 692 BRG., REACTION GEAR SUPPORT TO CASE
697 DEFLECTOR, OIL (HIGH
1 OUTPUT MODELS ONLY) JH0092-700Rd I 1 I Figure 106 Reaction lnternal Gear and Carrier Bearing
Locations
Lo and Reverse Support Assembly
Remove or Disconnect (Figure 11 1)
1. Inner race (675) from the support assembly
2. One retainer ring (677)
3. Roller clutch assembly (678)
@ inspect (figure I 11)
e Inner race (675) for damage and surface finish
a Roller clutch assembly (678) for
- damaged rollers
- broken springs
a Cam and support assembly for
- loose cam
- surface finish
- cracks or damaged lugs.
Install or Connect (Figure 11 1 and 112)
1. Roller clutch assembly (678) into the cam and
support assembly (679)

AUTOMATIC TRANSMISSION 700.R4-21
INSTALL THE APPROPRIATE SELECTIVE
SPACER PLATE TO THE FINAL
ASSEMBLY AFTER DIMENSION "D"
IS OBTAINED. IDENTIFICATION
SIDE UP.
682(B) WAVED
STACK UP FOR
MEASURING
ILL. NO. DESCRIPTION
679 SUPPORT ASSEMBLY, LO & REVERSE CLUTCH
682 PLATE ASSEMBLY, LO & REVERSE CLUTCH 682(A) SPACER PLATE, LO & REVERSE CL. (SELECTIVE) 682(B) WAVE PLATE, LO & REVERSE CLUTCH
Figure 107 Measuring For Back Plate Selection
LO & REVERSE CLUTCH SPACER PLATE SELECTION CHART
I IF GAGE DIMENSIONS 'D' IS I USE THIS SELECTIVE PLATE I
FROM IDENTIFICATION
28.844mm
(1 .I 36") I NONE
Figure 108 Lo and
Reverse Backing Plat
PLATE THICKNESS
JH0190-700R4
? Selection Chart
2. Support and roller assembly into the case with the Reaction Sun Gear and Shell hub down
3. Inner race (675) into the roller assembly
Inspect (Figure 11 4)
4. Turn inner race (675) while inserting e Reaction Sun Gear (673) for - push down for full engagement.
- bottom tangs will be flush with carrier hub - nicked, scored, or worn bushing. (See
when properly installed. Bushing Replacement).
- check for
proper operation by rotating'the - damaged spline or teeth
inner race as shown in Figure
11 1. - loose or weak retaining ring (do not remove
5. Support retainer spring (680) into the case this
ring, except to replace it.)
- insert between the case lug and the one open @ Reaction sun shell (670) for
notch in the support. - stripped or worn splines

700-R4-22 AUTOMATIC TRANSMISSION
I PLATE-COMP. FACED 2.25mm
1 1 (.088") I
I PLATE-SELECTIVE I 1 I SEE FIG. 108 1
PLATE - WAVED 2.43mm
Figure 109 Lo and Reverse Clutch Plate Chart
10 CASE, TRANSMISSION
682 PLATE ASSEMBLY,
LO&REVERSECLUTCH
Figure 110 Lo and Reverse Clutch Plates Properly Installed
- broken hub
- bent tangs
e I,o and reverse inner race to reaction sun gear
shell thrust washer (674) for wear or damage
e Reaction shaft to reaction sun gear shell thrust
washer (669) for wear or damage (bronze thrust
washer).
Install or Connect (Figure 4 44 and 1 15)
1. Reaction sun gear retainer ring (671) onto the
reaction sun gear, if previously removed.
2. Reaction sun gear (673) into the reaction carrier
- index the teeth with the pinion gears.
3. Thrust washer (674) onto the lo and reverse
support inner race
- index the four locating ears into the inner
race.
4. Reaction gear shell (670) onto the reaction sun
gear
5. (Bronze) thrust washer (669) onto the reaction . , sun shell
- index tangs into the shell.
A LOCKEDUP
B FREE WHEELS
675 RACE, LO
& REVERSE ROLLER CLUTCH
677 RING, LO & REVERSE RETAINER (ROLLER ASSEMBLYICAM) 678 CLUTCH ASSEMBLY, LO & REVERSE ROLLER
679 SUPPORT ASSEMBLY, LO 81 REVERSE CLUTCH
680 SPRING, TRANSMISSION LO & REVERSE
CLUTCH SUPPORT R ETA1 NE R ~~oog5.700~4 - -- Figure I I I Lo and Reverse Clutch Support Assembly
Align Wide Notch
with
Wide Case Lug.
I I Figure 1 12 Lo and Reverse Support and Roller Asm.
Installation
Input Internal Gear and Output Shaft
Remove or Disconnect (Figure 11 6)
1. Retainer ring (668) from input internal gear (664)
2. Reaction carrier shaft (666) from the input
internal gear

AUTOMATIC TRANSMISSION 700-R4-23
Y, LO & REVERSE ROLLER
662 CARRIER ASSEMBLY, INPUT
- COMPLETE
663 BEARING ASSEMBLY, THRUST (INPUT
CARRIER TO REACTION SHAFT)
666 SHAFT, REACTION CARRIER
669 WASHER, THRUST (REACTION
SHAFTISHELL) 670 SHELL, REACTION SUN
673 GEAR, REACTION SUN
674 WASHER, THRUST
(RACE/REACTION SHELL)
675 RACE, LO
& REVERSE ROLLER CLUTCH
Thrust Washer Locations
10 CASE, TRANSMISSION
669 WASHER, THRUST (REACTION
SHAFT/SHELL)
670 SHELL, REACTION SUN 664 GEAR, INPUT INTERNAL
666 SHAFT, REACTION CARRIER
671 RING, REACTION SUN GEAR RETAINER 668 RING, REACTION
SHAFTIINTERNAL GEAR
673 GEAR, REACTION SUN RETAINER
674 WASHER, THRUST
(RACEIREACTION SHELL)
675 RACE, LO
& REVERSE ROLLER CLUTCH Figure 11 6
Input Internal Gear and Reaction Shaft
676 RING, LO
& REVERSE SUPPORT TO CASE - scored, damaged, or worn bushings (see
Bushing Replacement)
Figure 1 14 Sun Gear and Shell Installation - cracked shaft
- damaged spline or gear teeth
Inspect (Figures 1 15, 1 16, and 1 18) - under cut around the shaft from
interference with the sun gear
e Reaction Carrier Shaft (666) for
Input internal gear (664) for

"1QO-R4-24 AUTOMATIC TRANSMISSION
- cracks
- damaged spline or gear teeth
Input carrier to reaction shaft thrust bearing
(663) for wear or damage
Ouput shaft (687)
- plugged or restrictred lube passages
- damaged splines or ring groove
- damaged governor drive gear teeth
- burrs or damage to the front of the shaft at
seal area. (Polish with crocus cloth if
necessary)
- burrs or damage to bearing journals
- damaged teeth on speed sensor rotor
Internal Transmission Speed Sensor Rotor
REMOVE ONLY IF DAMAGED
TOOLS REQUIRED:
J-2 1427-0 1 speedometer gear puller adapter
5-8433 speedometer gear puller
J-36352 speedometer gear installater
& "C"
washer
Mechanical press
1. Install J-21427 with J-8433 and remove rotor.
2. Place new rotor over output shaft.
3. Place J-36352-1 in groove on output shaft.
- DO NOT REUSE ROTOR
4. Place 5-36352-2 on shaft and press to make
contact with
5-36352- 1.
L TRANSMISSION SPEED
Fig. 1 17 Internal f ransmission Speed Sensor Rotor
Install or Connect (Figures 1 16 and 1 18)
1. Reaction shaft (666) into the input internal gear
(664)
2. Retainer ring (668) into the input internal gear
3. Input internal gear and shaft assembly into the
sun gear shell
- index the shaft spline into the reaction
carrier.
4. Thrust Bearing (663) onto the reaction carrier
shaft.
- outer race goes toward the reaction carrier
shaft.
5. Output shaft (687) into the transmission
- index the splines with the mating parts.
6. J-29837 onto the case
- position upwards as far as possible to
support the output shaft.
Figure 1 18 Output Shaft - Installation
Input Carrier and Sun Gear
Inspect (figures 1 19 and 120)
e Input carrier assembly (662) for
- pinion gear damage
- excessive pinion washer wear (end play 20-.
61 mm/.008-.024 in,)
- proper pin stake
- keystoned pinion gears (pinion gears must
rotate freely)
- damaged or worn thrust bearing
e Input sun gear (658) for
- bushing damage or wear (see Bushing
Replacement Procedure).
- cracks
- damaged spline or gear teeth
Install or Connect (Figure 1 19)
TOOLS REQUIRED:
5-34627 Snap Ring Pliers
1. Input carrier assembly (662) onto the output
shaft
2. Retainer ring (661) into the output shaft ring
groove
- Do not reuse the old retainer ring if it has
been overexpanded.
- Use care not to overexpand the ring during
installation.
3. Remove J-29837.
4. Input sun gear (658) into the input carrier
- index the sun gear teeth into the pinion gear
teeth.

AUTOMATIC TRANSMISSION 700-R4-25
10 CASE, TRANSMISSION
658 GEAR, INPUT SUN 661 RET., OUTPUT SHAFT TO INPUT CARRIER 662 CARRIER ASSEMBLY, INPUT -COMPLETE 663 BEARING ASSEMBLY, THRUST (INPUT
CARRIER TO REACTION SHAFT)
JH0102-700R4
Figure 1 19 lnput Carrier and Sun Gear - Installation
662 CARRIER ASSEMBLY, INPUT -COMPLETE 690 SLEEVE, OUTPUT SHAFT JHOO~O-700~4
Figure 120 Checking Captured Thrust Bearing
lnput Clutch Assembly
Remove or Disconnect (Figure 121)
e Reverse input clutch assembly (605) from the
input clutch assembly (62 1)
e Oil pump to selective washer thrust bearing (61 5)
e Selective washer (616)
605 HOUSING & DRUM ASSEMBLY, REVERSE
INPUT CLUTCH
615 BEARING ASSEMBLY, STATOR SHAFT1 SELECTIVE WASHER
616 WASHER, THRUST (SELECTIVE) 621 HOUSING & SHAFT
ASSEMBLY, INPUT
~~0103-700134
Figure 12 1 Reverse lnput and lnput Clutches
+'+ Disassemble (Figures 123 and 124) (I]
TOOLS REQUIRED:
J-23456 Clutch Spring Compressor Press
J-25018 Clutch Spring Compressor
1. Place the input clutch assembly (621) on the
bench with the turbine shaft through the bench
hole.
2. The 3-4 clutch plate retainer ring (656) and the
backing plate (655)
3. The
3-4 clutch plates (654)
4. The 3-4 clutch apply plate (653)
5. The 3-4 clutch ring retainer plate (652)
6. Forward
clutch backing plate retainer ring (65
1)
and backing plate (650)
7. Forward clutch sprag assembly (638 - 644)
Disassem bie
1. Input sun gear bearing assembly (637)
2. Input
housing to output shaft lip seal (636).
3. Forward clutch plates (649)
4. Forward wave plate (648)
5. Forward clutch apply plate (646)

700-84-26 AUTOMATIC TRANSMISSION
SHOULDER
INSTALLATION
A ROD STOCI 620 RETAINER
& CHECK BALL ASSEMBLY
621 HOUSING
& SHAFT ASSEMBLY, INPUT
698 PLUG, ORIFICED CUP JH0104-700R4
Figure 122 Retainer and Check Ball Removal/lnstallation
6. Overrun clutch plates (645)
Disassemble
1. Install J-23456 and J-25018
- Compress overrun clutch spring assembly
(634).
2. Overrun clutch retainer ring (635).
3. Overrun clutch spring assembly (634).
4. Overrun clutch piston (632)
- inner and outer lip seals (631)
5. Forward clutch piston assembly (630)
- inner and outer lip seals (629)
6. Forward clutch housing (628)
7. The 3-4 clutch spring assembly (626)
8. The 3-4 clutch apply ring (625) and piston (623)
- inner and outer lip seals (624) from piston
9. Forward clutch to input housing
"0" ring seal
(622)
10.
Four turbine shaft oil seal rings (619)
Inspect (figure 126 and 127)
1.
Input housing for porosity or damage
2. Input housing and shaft assembly (621)
all splines for wear or damage
e air check feed passages.
three turbine shaft sealing balls
- the balls must not be loose or leaking. - the open hole is the lube oil passage
which feeds the output shaft.
a Presence of orificed cup plug (698)
a Cracks at lube holes.
@ Four turbine shaft oil seal rings (619) and
their ring grooves for damage, burrs, or cuts
- these seals must fit freely into the ring
grooves.
o Check valve retainer and ball assembly
(617) for damage
- the ball must move freely in the
retainer.
- the retainer must be tight in the
turbine shaft.
Check Valve Retainer and Ball Assembly -
Replacement Procedures
Remove or Disconnect (Figure 125)
TOOLS REQUIRED:
#4 Screw extractor
1. Straighten the tangs of the retainer and
remove the ball.
2. Check valve retainer
- use #4 Screw Extractor
Install or Connect (Figure 125)
TOOLS REQUIRED:
9.5 mm
(3/8") diameter metal rod
e New check valve retainer and ball assembly
(6 17) - use the 9.5 mm (3/8") metal rod.
- seat the retainer 3.0 mm (1/8 in.)
below top surface of the turbine shaft.
- be certain the ball is loose.
lnspect (Figure 126 and 127)
@ Turbine shaft "0" ring seal (61 8) for nicks, cuts,
or damage
Input housing check valve ball (620).
- the ball must move freely. - leak check the ball with solvent.
Important (Figure 126)
o If the 3-4 clutch plates are burned or
worn and a cause is not found during
diagnosis or disassembly, replacement
of the retainer and check ball assembly
may be required.
Remove or Disconnect (Figure 122)
TOOLS REQUIRED:
5.715 mm
(1/4") diameter rod or drift hammer

AUTOMATIC TRANSMISSION '900-R4-27
ILL. NO. DESCRIPTION
61 5 BEARING ASSEMBLY, STATOR SHAFT/ SELECTIVE WASHER
61 6 WASHER, THRUST (SELECTIVE)
620 RETAINER
& CHECK BALL ASSEMBLY
621 HOUSING & SHAFT ASSEMBLY, INPUT
623 PISTON, 3RD & 4TH CLUTCH
625 RING, 3RD & 4TH CLUTCH APPLY
626 SPRING ASSEMBLY, 3RD & 4TH CLUTCH
628 HOUSING, FORWARD CLUTCH
630 PISTON, FORWARD CLUTCH
632 PISTON, OVERRUN CLUTCH
634 SPRING ASSEMBLY, OVERRUN CLUTCH
635 SNAP RING, OVERRUN CLUTCH SPRING
RETAINER
636 SEAL, INPUT HOUSING TO OUTPUT SHAFT
645 PLATE ASSEMBLY, OVERRUN CLUTCH
A FORWARD CLUTCH SPRAG ASSEMBLY
637 BEARING ASSEMBLY, INPUT SUN GEAR
638 SNAP RING, OVERRUN CL. HUB RET.
639 HUB, OVERRUN CLUTCH
641 RETAINER
& RACE ASSEMBLY, SPRAG
642 FORWARD SPRAG ASSEMBLY
643 RETAINER RINGS, SPRAG ASSEMBLY
644 RACE, FORWARD CLUTCH (OUTER) 646
PLATE, FORWARD CLUTCH APPLY
648
PLATE, FORWARD CLUTCH (WAVED)
649 PLATE ASSEMBLY, FORWARD CLUTCH
650 PLATE, FORWARD CLUTCH BACKING
(SEL.) 651 RING, FORWARD CLUTCH BACKING PLATE
RETAINER
652 PLATE. 3RD
& 4TH CLUTCH RING RETAINER
653 PLATE; 3RD & 4TH CLUTCH APPLY ISTEPPED)
654 KATE ASSEMBLY, 3RD & 4TH CLUTCH
655 PLATE, 3RD & 4TH CLUTCH BACKING (SEL.) 656 RING, 3RD & 4TH CLUTCH BACKING
PLATE RETAINER
657 BUSHING, INPUT SUN GEAR (FRONT)
698 PLUG,
ORIFICED CUP
Figure 123 Input Clutch Assembly

700-R4-28 AUTOMATIC TRANSMISSION
Figure 124 Overrun Clutch Retainer Ring - Removal
REMOVE
"
A #4 EASY OUT
B TURBINE SHAFT
C 9.5MM (318 IN.) METAL ROD
617 CHECK VALVE RETAINER
& BALL ASSEMBLY ~~0107-700~4
Figure 125 Retainer and Ball Assembly - Replacement
1. Tap out retainer and ball assembly.
Install or Connect (Figures 122 and 126)
1. Using same tools, tap in retainer and ball
assembly until shoulder is seated in housing.
Inspect (Figure 123)
e The 3-4 clutch piston (623) for damage or
porosity
e The 3-4 clutch apply ring (625) for
- bent tangs
The 3-4 clutch spring
assemby for damage or
distortion
Assemble (Figure 128)
1. Position the input housing and shaft assembly on
the bench with the turbine shaft through a bench
hole.
2. Inner and outer 3-4 clutch lip seals (624) on the
3-4 clutch piston
- seal lips must face away from the piston
hub.
- lubricate the seals with transmission fluid.
3. The 3-4 clutch piston (623) into the input housing
as shown
615 BEARlNGASSEMBLY,STATORSHAFT/
SELECTIVE WASHER
616 WASHER, THRUST (SELECTIVE)
620 RETAINER & CHECK BALL ASSEMBLY
621 HOUSING &SHAFT ASSEMBLY, INPUT
636 SEAL, INPUT HOUSING TO OUTPUT SHAFT 687 SHAFT, OUTPUT 698 PLUG, ORIFICED CUP JH0108-70084
Figure 126 lnput Housing Check Valve Ball
USED
WlTH MM CONVERTER
.621
USED WITH 245 MM CONVER
TER
A
SHAFT,TURBINE
618 SEAL, "0" RING (TURBINE SHAFT/ SELECTIVE WASHER) 621 HOUSING & SHAFT
ASSEMBLY, INPUT
JH0109-70084
Figure 127 Views of the lnput Housing
- use care not to damage the seals.

AUTOMATIC TRANSMISSION "/O-R4-29
1 621 HOUSING & SHAFT
ASSEMBLY, INPUT
623 PISTON, 3RD
& 4TH CLUTCH
624 SEALS, 3RD &4TH CLUTCH (INNER & OUTE
Figure 128 Input Housing and 3-4 Piston
Inspect (figures 123, 129, 131)
Forward clutch housing (628) for
- proper check ball operation
- damage or distortion
- burrs in seal areas
- cracks
Forward clutch piston
(630) and overrun clutch
piston
(632) for
- porosity or damage
- ring groove damage
- apply leg damage
e Overrun spring assembly (634) for damage or
distortion
e Input housing to output shaft lip seal (636) for
damage or wear
Assemble (Figures 129 and 130)
TOOLS REQUIRED:
5-23456 Clutch Spring Compressor Press
5-25018 Clutch Spring Compressor
J-29882 Overrun Clutch Inner Seal
Protector
J-29883 Forward Clutch Inner Seal
Protector
1. Forward clutch housing to input clutch housing
"0" ring seal (622) as shown
- lubricate with transmission fluid.
2. Inner and outer seals (629) on forward clutch
piston
- seal lips must face away from the piston
tangs as shown.
- lubricate with transmission fluid.
3. Forward clutch piston (630) into the forward
clutch housing
- use care not to damage the outer lip seal.
4. The 3-4 clutch spring assembly (626) onto the 3-4
clutch apply ring
5. Forward clutch assembly onto the 3-4 clutch
spring assembly
- the forward clutch piston apply legs must be
indexed with the 3-4 clutch apply ring legs.
6.
J-29883 on the input housing as shown
7. Apply ring and forward clutch assembly into the
input housing as shown
- hold the assembly by the apply ring legs
during installation.
- do not let the forward clutch piston separate
from the housing.
- firmly seat the assembly.
8. J-29882 on the input housing as shown
9. Overrun clutch piston (632) - hub facing upward as shown. - if all parts are properly seated to this point,
the overrun piston hub will be
approximately
3/16 in. below the snap ring
groove in the input housing hub.
HOUSING 13( SHAFT ASSEMBLY, INPUT
SEAL, O-RING (INPUTIFWD. HSG.) PISTON, SRD & 4TH CLUTCH
RING, 3RD & 4TH CLUTCH APPLY
SPRING ASSEMBLY, 3RD & 4TH CLUTCH
HOUSING, FORWARD CLUTCH
SEALS, FWD. CLUTCH (INNER
& OUTER)
PISTON, FORWARD CLUTCH
JH0112-700R4
Figure 129 Forward Clutch and 3-4 Apply Ring - Installed
Assemble (Figures 1311 and 132)
1. Overrun clutch spring assembly (634) onto the
overrun clutch piston.
- locate the springs on the piston tabs
2. 5-23456 and J-25018 onto the overrun spring
assembly.
- compress springs (Do not over-compress).
3. Retainer snap ring (635) into the snap ring groove
4. Input housing to output shaft lip seal (636)
a Inspect
e Overrun clutch plates (645)