PONTIAC FIERO 1988 Service Repair Manual

700-R4-60 AUTOMATIC TRANSMISSION
PROTECT PARTS WITH WOOD BLOCKS OR CLOTH AS NECESSARY
4 BUSHING, STATOR SHAFT - FRONT
90 BUSHING, STATOR
SHAFT
- REAR
217 COVER, PUMP 4 BUSHING, STATOR SHAFT - FRONT
90 BUSHING, STATOR SHAFT
- REAR
217 COVER, PUMP
3 BUSHING, OIL PUMP BODY
203 BODY, PUMP 3 BUSHING, OIL PUMP BODY
203 BODY, PUMP
603 BUSHING, REVERSE INPUT CLUTCH
- FRONT
605
HOUSlNG&DRUMASSEMBLY, REVERSE
INPUT CLUTCH
606 BUSHING, REVERSE INPUT CLUTCH
- REAR 603
BUSHING, REVERSE INPUT CLUTCH
- FRONT
605 HOUSING & DRUM ASSEMBLY, REVERSE
INPUT CLUTCH
606 BUSHING, REVERSE INPUT CLUTCH
- REAR
Figure 206 Bushing Replacement Procedure

AUTOMATIC TRANSMISSION 700-R4-61
I PROTECT PARTS WITH WOOD BLOCKS OR CLOTH AS NECESSARY I
657 BUSHING,
INPUT SUN GEAR - FRONT
658 GEAR, INPUT SUN
659 BUSHING,
INPUT SUN GEAR
- REAR --------------
665 BUSHING, REACTION CARRIER SHAFT -
FRONT
666 SHAFT, REACTION CARRIER
667 BUSHING, REACTION CARRIER SHAFT
-
REAR --------------
657
BUSHING, INPUT SUN GEAR - FRONT
658 GEAR, INPUT SUN
659 BUSHING, INPUT SUN GEAR
- REAR --------------
665 BUSHING, REACTION CARRIER SHAFT - FRONT
666 SHAFT, REACTION CARRIER
667 BUSHING, REACTION CARRIER SHAFT
- REAR -----up------
672 BUSHING, REACTION SUN 672 BUSHING, REACTION SUN
673 GEAR, REACTION SUN
JH0170-700R4
Figure 207 Bushing Replacement Procedure

700-R4-62 AUTOMATIC TRANSMISSION
BUSHING REPLACEMENT PROCEDURE
PROTECT PARTS WITH WOOD BLOCKS OR CLOTH AS NECESSARY
36 EXTENSION, CASE
38 BUSHING, CASE EXTENSION
10 CASE, TRANSMISSION
76 BUSHING, CASE 36
EXTENSION, CASE
38 BUSHING, CASE EXTENSION
Figure
208 Bushing Replacement Procedure

AUTOMATIC TRANSMISSION 700-R4-63
GOVERNOR BORE REPAIR PROCEDURE
FOLLOW STEPS 1-6 TO REPAIR THE GOVERNOR BORE
STEP
1 Install holding fixture J-8763 and mount in vise.
STEP
2 Remove (file) any excess material from the
governor face.
B RATCHET & SOCKET
STEP
4 Ream the governor bore as follows: @ Oil J-22976-9, J-22976-1 and the governor bore
with transmission fluid.
@ After each ten revolutions, remove the reamer
and dip in transmission fluid to clean.
@ After the reamer reaches the end of the bore and
bottoms on the governor support pin, rotate the
reamer ten additional revolutions.
Remove the reamer. Be certain to rotate during
removal to prevent scoring the bore.
Remove the tools and thoroughly clean the case.
C
C BUSHING
D SLOTS
STEP
5 Align the slots in the bushing with the slots
in the governor bore.
A PIN, GOVERNOR SUPPORT
10 CASE, TRANSMISSION
STEP
3 Install J-22976-3 and J-22976-1. Torque bolts
to 13 N.m (10 ft.-lbs.). Make sure J-22976-3
rotates freely and then remove it. *
C BUSHING
E BRASS HAMMER
STEP
6 Install the bushing until the slots in the bushing
align with the feed holes in the governor bore.
Figure 209 Governor Bore Repair Procedure

780-R4-64 AUTOMATIC TRANSMISSION
-
Universal Remover Dial Indicator Set
I - -
1 Pump Oil Seal Installer I Piston Compressor 1 Bushing Remover I
Clutch Spring Compressor Clutch Spring
Compressor
J-25022
End Play Checking Fixture Adaptor Bushing
Remover
Figure
2 10 Special Tools

AUTOMATIC TRANSMISSION 7A-1
SECTION 7
AUTOMAT C TRANSM
CONTENTS
GENERAL INFORMATION AUTOMATIC TRANSMISSION .................................... 7A
ON VEHICLE SERVICE .................................................................................................. 7A 1
700-R4 UNIT REPAIR .................................................................................................. 700-R4
SECTION 7A
TRANSM ON GENERAL NFORMAT
CONTENTS
TRANSMISSION IDENTIFICATION NOISE AND VIBRATION
INFORMATION
..................... .. .............. 7A- I ANALYSIS .................... .... .............. 7A-3
TRANSMISSION DEFINITIONS TRANSMISSION FLUID LEVEL
Throttle Positions
.......................... .. ..... 7A-2 INFORMATION ....................................... 7A-3
Shift Conditions .................................... .... . 7A-2 TRANSMISSION FLUID LEVEL
Noise Conditions
....................................... 7A-2 CHECKING
PRELIMINARY CHECKING PROCEDURE
............................................ 7A-3
PROCEDURE
......................................... 7A-3
The information contained in this section is common to all automatic transn~issions. For on-vehicle service
procedures refer to Section
7A1. For complete Diagnosis and Unit Repair refer to the specific transrllission sections.
For vehicles sold in Canada also refer to the appropriate Canadian Service Manual Supplement for-
driveuhility
diagnosis.
TRANSMISSION IDENTIFICATION Additional Transmibsion identification is pr-ov~dcd
INFORMATION on the Service Parts Identification label. This labcl
contains information on the regular production option
(RPO) as well as standard and mandatory options. Th14
label is affixed to the inde of each vehrcle at thc
assembly plant. Refer to Section OA of this Scrvice
All automatic transmissions have a metal Manual for label location and information.
identification nameplate attached to the case exterior.
The location of this name plate is shown in Figure
1.
The information on the nameplate will assist in the
servicing and determination of replacement parts when
ordered through a GM Parts Catalog.
r----------- I ADDITIONAL IDENTIFICATION: MODEL YEAR I FOR SOME MODELS
THM 700-R4 TRANSMISSION IDENTIFICATION INFORMATION TOLEDO, OHIO A & B = FIRST SHIFT
JH0192-700R4
Figure 1 Transmission Identification Information

7A-2 AUTOMATIC TRANSMISSION
I I
M - INDICATES TRANSMISSION
TYPE IN OPTION LIST. (SPECIFIC MODEL CODE IS FOUND ON THE I MX - DESIGNATES
11 SERVICE PARTS IDEMTIFICATIOM I 1 00 MOT REMOVE I
1G3AR47YXE5
C90 C95 DF3 D3C 033 0 GI GW9 G60 GU2 G89
JAl JA4 KO5 K22 Kg9 LV2 NA5 NB1 NKl NK3 N33 N67 GJW
T87 UJ3 U23 U35
VO8 V10 WC3 WG2 YT9 Y56 OIL 6SC 428 421 420
Figure 2 Service Parts ldentificaiton Label
TRANSMISSION DEFINITIONS
The following definitions are being provided to
establish a common language and assist the user in
describing transmission related conditions. Some of
these terms or conditions are used in the transmission
sections of this Service Manual.
Throttle Positions
Minimum Throttle - the least amount of
throttle opening required for an upshift.
Light Throttle - approximately 1/4 of
accelerator pedal travel.
Medium Throttle - approximately 1/2 of
accelerator pedal travel.
Heavy Throttle - approximately 3/4 of the
accelerator pedal travel.
Wide Open Throttle (WOT) - full travel of
the accelerator pedal.
Full Throttle Detent Downshift - a quick
apply of the accelerator pedal to its full travel,
forcing a downshift.
Zero Throttle Coastdown - a full release of
the accelerator pedal while the vehicle is in
motion and in drive range.
Engine Braking - a condition where the engine
is used to slow the vehicle by manually
downshifting during a zero throttle coastdown.
Shift Conditions
'a Bump - a sudden and forceful apply of a clutch
or band.
Q Chuggle - a bucking or jerking condition that
may be engine related. May be most noticeable
when the converter clutch is engaged. Similar to
the feel of towing a trailer.
e Delayed - a condition where a shift is expected
but does not occur for a period of time. Samples
of this condition could be described as clutch or
band engagement does not occur as quickly as
expected during a part throttle or wide open
throttle apply of the accelerator or, when
manually downshifting to a lower range. Also
defined as "LATE" or, "EXTENDED."
Double Bump ("Double Feel") - two sudden
and forceful applies of a clutch or band.
Early - a condition where the shift occurs before
the vehicle has reached a proper speed and tends
to labor the engine after the upshift.
End Bump - a firmer feel at the end of a shift as
compared to the feel at the start of the shift. Also
defined as "END FEEL" or, "SLIP BUMP."
Firm - a noticeable quick apply of a clutch or
band that is considered
normal with a medium
to heavy throttle shift. Should not be confused
with "HARSH" or "ROUGH."
Flare - a quick increase in engine rpm
accompanied with a momentary loss of torque.
This most generally occurs during a shift. Also
defined as "SLIPPING.
"
Harsh ("Rough") - a more noticeable apply of
a clutch or band as compared to "FIRM." This
condition is considered undesireable at any
throttle position.
Hunting - a repeating quick series of upshifts
and downshifts that causes a noticeable change in
engine rpm. An example could be described as a
4-3-4 shift pattern. Also defined as
"BUSYNESS.
"
Initial Feel - a distinct firmer feel at that start
of a shift as compared to the finish of the shift.
Late - a shift that occurs when the engine is at
a higher than normal rpm for a given amount of
throttle.
Shudder - a repeating jerking sensation similar
to "CHUGGLE" but more severe and rapid in
nature. This condition may be most noticeable
during certain ranges of vehicle speed. May also
be used to define the condition after converter
clutch engagement.
Slipping - a noticeable increase in engine rpm
without a vehicle speed increase.
A slip usually
occurs during or after initial clutch or band
engagement.
Soft - a slow, almost unnoticeable clutch apply
with very little shift feel.
Surge - a repeating engine related feeling of
acceleration and deceleration that is less intense
than "CHUGGLE.
"
Tie-Up - a condition where two opposing
clutches are attempting to apply at the same time
causing the engine to labor with a noticeable loss
of engine rpm.
,e Conditions
Gear Noise - a whine, most noticeable in first
gear and reverse that is related to vehicle speed.
A gear noise condition may become less
noticeable or go away after an upshift.
Pump Noise - a high pitch whine that increases
in intensity with engine
rpm. This condition may
also be noticeable in
"PARK" and "NEUTRAL"
operating ranges with the vehicle stationary.

AUTOMATIC TRANSMISSION 7A-3
PRELIMARY CHECKING PROCEDURE
The condition of an automatic transmission not
operating properly may be influenced by one, or a
combination of the following items:
e Fluid level high/low
(Refer to Section 7A1)
e Engine performance
(Refer to Sections 6 and 6E)
T.V. cable adjustment
(Refer to Section
7A1)
e Manual linkage adjustment
(Refer to Section
7A1)
e Internal fluid leaks
(Refer to Transmission Unit Repair section)
e Electrical system
(Refer to Section 6E and 8A)
e Transmission or other mechanical component
(Refer to Transmission Unit Repair section)
e Vacuum modulator
(Refer to appropriate Hydraulic Diagnosis
Section)
NOISE AND VIBRATION ANALYSIS
A noise or vibration that is noticeable when the
vehicle is in motion, MAY NOT be the result of the
transmission.
If noise or vibration is noticeable in "Park"
(P)
and "Neutral" (N) with engine at idle, but is less
noticeable as
RPM's increase, the cause may be from
poor engine performance.
e Tires for
- Uneven wear
- Imbalance
- Mixed sizes
- Mixed radial and bias ply
(Refer to Section 3E)
e Suspension components for
- Alignment and wear
- Loose fasteners
(Refer to Section 3C)
e Engine/Transmission mounts for
- Damage
- Loose bolts
(Refer
to Sections 6A and 7A2)
e Transmission case mounting holes for:
- Missing bolts, nuts, studs
- Stripped threads
- Cracks
e Flywheel for:
- Missing or loose bolts
- Cracks
- Imbalance
(Refer to Section 6A)
e Torque converter for: - Missing or loose bolts or lugs - Missing or loose balance weights
- Imbalance
TRANSMISSION FLUID LEVEL INFORMATION
Checking fluid level, color and condition at
regular intervals will provide early diagnosis
information about the transmission. This information
may then be used to correct a condition that, if not
detected early, could result in major transmission
repairs.
When adding or changing fluid, use only
DEXRONO 11, or equivalent. Refer to Section OB of
this Service Manual for maintenance information and
servicing intervals.
Fluid level should be checked when it reaches
normal operating temperatures of
190-200°F.
(88-93°C). This temperature is reached after
approximately 15 miles (24 km) of highway
driving.
e Fluid color - Should be dark red (may be dark green)
NOTICE: Do not overfill. Overfilling will cause
foaming, loss of fluid and possible damage to the
transmission.
Inaccurate fluid level readings will result if
checked immediately after the vehicle has been
operated:
- In high abmient temperatures above 90°F
(32°C)
- At sustained high speeds
- In heavy city traffic during hot weather
- As a towing vehicle - In commercial service (taxi or police use)
TRANSMISSION FLUID CHECKING
PROCEDURE
(Refer to Figure 3)
1. Park vehicle on level ground.
2. Apply parking
brake and block wheels.
3. Start
engine and operate vehicle for 15 minutes or
until a normal operating temperature is reached.
4. Move gear
selector through all gear positions.
5. Move
gear selector to "Park" (P).
6. Check fluid level, color and condition.

7A-4 AUTOMATIC TRANSMISSION
HOT FULL
Lcom FULL
I CHECKING FLUID COLOR, LEVEL AND CONDITION 1
CHECK FOR EXTERNAL
LEAKS (REFER TO
SECTION
7A21 I I
- TRANSMISSION OVERHAUL
REQUIRED (REFER TO
UNIT REPAIR SECTION)
I
CHECK FOR CONTAMINATION 4 (REFER TO SECTION 71\21 1
REFER TO SECTION 7A2
FOR CONDITION OF FLUID I
Figure 3 Checking Fluid Color, Level and Condition

AUTOMATIC TMNSMISSION ON-VEHICLE SERVICE 7A1-1
SECTION 7Al
AUTOMAT C TRANSM
ON VEH CLE SERV
CONTENTS
GENERAL SERVICE T.V. Cable
PROCEDURES Diagnosis ........................ .. ....................... 7A 1-6
Parts Cleaning, Inspection and
Replacement
....................................... 7A1-7
Replacement
............................ ... .... 7A1- 1 Adjustment ............................................. 7A1-7
Flexplate/Torque Converter Changing Fluid and Filter ............................. 7A1-7
........................... Vibration Test Procedure 7A1-2 700-R4 Serviceable Components
Fluid Leak Diagnosis
..................................... 7A 1-2
Servo Assembly .......................................... 7A 1-7
Methods For Locating Leaks
.................... 7Al-2 Speedometer Drive Gear .............................. 7A 1-1 1
Repairing the Leak .................................. 7A 1-2 Spccdomctcr Driven Gciu .......................... 7A1-1 1 Possible Points of Fluid Leaks .................. 7A1-2 Governor ............................................. 7A 1- 1 1
Case Porosity Repair .................................. 7A 1-3 Filler Tube .............................................. 7A1-12
Torque Converter Clutch
Pressure Regulator Valve
........................... 7A 1- 12
Electrical Controls
.................................. 7Al-3
Auxiliary Valve Body ................................. 7A1-13
Diagnosis
................................... .... ........ 7A 1-3 Valve Body ............................................. 7A 1- 13
ON-VEHICLE SERVICE Rear Oil Seal ............................................ 7A 1- 14
Shift Control Cable
Oil Cooler Lines And Fittings
................... 7A1-14
Replacement
............................................ 7A 1-3 Oil Cooler Flushing .............................. 7A 1 - 14 ................................................ Adjustment 7A1-3 Transmission Assenlbly Removal and
Floor Shift Control
................... .. ................ 7A1-3
Installation ........................... .. ............ 7A1- 14
Park/Lock Control Cable .............................. 7A 1-4
Park/Neutral and Back Up Lamp
Switch
................................................. 7A1-5
GENERAL SERVICE PROCEDURES
PARTS CLEANING, INSPECTION AND
REPLACEMENT
Use appropriate safety equipment such as:
- Safety glasses
- Safety shoes
- Gloves
Keep work area and tools clean
Clean transmission exterior before removing
parts
Do not use wipe cloths or rags
Do not use solvents on:
- Rubber seals
- Plastic/Teflon@ thrust washers
Blow out all passages with compressed air
Clean out small passages with fine wire
Handle parts carefully to prevent damage
Lubricate all internal parts with transmission
fluid during assembly
When installing screws, bolts or studs into
aluminum always dip the threads in transmission
fluid
Always use a torque wrench for proper torque
€3 Recondition damaged or stripped aluminum
threads with thread inserts
@ Replace all gaskets and o-ring seals
- Do not use gasket cement or sealers
@ Replace Teflon@ and rubber lip seals only when
necessary and install using the appropriate seal
protector
s Manual linkage for:
- Wear at pivoting points - Bent or broken links and rods
s All seals, gaskets, o-rings and mating surfaces for:
- Nicks
- Cuts
- Damage
€3 Snap rings for:
- Expansion or compression
- Distortion
- Nicks
- Proper ring to groove fit
s Bearings and thrust surfaces for:
- Wear
- Scoring