PONTIAC FIERO 1988 Service Repair Manual

7A1-12 AUTOMATIC TRANSMISSION ON-VEHICLE SERVICE
SOME MODELS I--- - .-
10 CASE, TRANSMISSION 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 €31 WASHER ASSEMBLY 42 SEAL, "0" RING (SPEEDO FITTING TO
CASE EXTENSION)
43 FITTING ASSEMBLY, SPEEDO DRIVEN GEAR
44 GEAR, SPEEDO DRIVEN 45 GOVERNOR ASSEMBLY
46 COVER, GOVERNOR
98 NUT, FLANGED HEX
99 SPEED SENSOR, INTERNAL TRANSMISSION
100 STUD, DOUBLE END 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
FILLER TUBE
Remove or Disconnect (Fig. 1 1)
1. Fluid, level indicator.
2. Raise car and suitably support, see Section OA.
3. Bolt retaining filler tube to transmission.
4. Loosen tube from transmission.
5. Lower car.
6. Pull tube out of car from the top.
Install or Connect
1. Filler tube.
2. Raise car.
3. Locate filler tube on transmission.
- Use new filler tube seal.
4. Filler tube bolt to transmission.
@ 47 N.m (35 lbs, ft.) - V8
@ 75 N-m (55 lbs. ft.) - V6
5. Lower car.
6. Fluid level indicator.
e Check and adjust fluid level, see Section 7A.
e Inspect for leaks.
Fig. 9 Speedometer Drive/Driven Gears
688 CLIP, SPEEDO DRIVE GEAR
689 GEAR, SPEEDO DRIVE
699 ROTOR, INTERNAL TRANSMISSION SPEED
SENSOR
J10007-7A1 -F
Fig. 10 Drive Gear
1. V6- 75 N.rn (55 LBS. FT.) V8-47 N.rn (35 LBS. FT.)
2. FILLER TUBE
3. FLUID LEVEL INDICATOR
4. SEAL
Fig. 11 Filler Tube and Indicator
PRESSURE REGULATOR VALVE
Remove or Disconnect
1. Raise car and suitably support, see Section OA.
2. Drain transmission oil pan.
3. Oil pan and screen.
4. Compress
pressure regulator valve with small
screwdriver.

AUTOMATIC TRANSMISSION ON-VEHICLE SERVICE 7A1-13
A WASHER, WIRE RETAINING
33 CONNECTOR, ELECTRICAL
96 TUBE, AUXILIARY ACCUMULATOR VALVE
97 CLAMP, TUBE
374 BOLT, SPECIAL HEX HEAD (M6
X 1 X 161
375 BOLT, HEX HEAD lM6
X 1 X 35)
376 BOLT, HEX HEAD lM6 X 1 X 45) , 377 AUXILIARY ACCUM. VALVE BODY ASM. 710 BRACKET, PARKING LOCK
71 5 BOLT, PARKING LOCK BRACKET
Fig. I2 Auxiliary Accumulator Valve Body
5. Retaining ring and slowly release spring tension.
6. Pressure regulator bore plug, valve, spring and
guide. Refer to the specific Unit Repair Section
for inspection procedures.
Install or Connect
1. Pressure regulator valve assembly.
2. Compress valve and insert retaining ring.
3. Oil pan
and screen, using a new gasket.
4. Lower car.
Adjust
cs Transmission fluid level.
- Dexron I1 Automatic Transmission Fluid
AUXILLARY VALVE BODY
Remove or Disconnect (Fig. 12)
I. Negative battery cable
2. Raise car and suitably support, see Section OA.
3. Place drain
pan under transmission oil pan.
4. Oil pan bolts from the front and sides only.
5. Loosen rear bolts approximately (4) turns.
NOTICE: Do not damage case or oil pan sealing
surfaces.
6. Lightly tap oil pan with rubber mallet or pry to
allow fluid to drain.
7. Remaining oil pan bolts, oil pan and gasket.
8. Oil filter and "0" ring.
- "0" ring may be stuck in case.
9. Tube clamp (97).
10. Tube (96).
11. Bolts (374 thru
376), auxiliary valve body (377),
and check ball.
Inspect
e Refer to the Unit Repair Section for
disassembly and inspection procedures.
Install or Connect
Check ball in valve body.
- If necessary, use petroleum jelly to hold in
place.
Auxiliary valve body to valve body with bolts
(374 thru 376).
- 11 N-rn(8lbs.ft.)
Tube (96)
Clamp (97)
New oil filter and "OW-ring.
- Coat "0" with petrolatum.
Oil pan with new gasket.
All traces of old gasket material must be
removed from case and pan.
Oil pan bolts.
- 20 Nem (15 Ibs. ft.)
Lower car.
Fill transmission to proper level with Dexron
I1
fluid or equivalent, see Section 7A.
Negative battery cable
VALVE BODY
Remove or Disconnect
1. Negative battery cable.
2. T.V. cable at throttle lever.
3. Raise car, see Section OA.
4. Place
drain pan under transmission oil pan.
5. Oil pan bolts from the front and sides.
6. Loosen
rear oil pan bolts approximately 4 turns.
NOTICE: Do not damage transmission case or oil
pan sealing surfaces.
7. Lightly
tap oil pan with rubber mallet or pry to
allow fluid to drain.
8. Remaining oil pan bolts, oil pan and gasket.
9. Oil
filter and
"0" ring.
- "0" may be stuck in case.
10. Valve body bolts.
- Manual control valve link from range
selector inner lever.
- Throttle lever bracket from T.V. link.
- Spacer plate and check balls.
Oil pan and case of gasket material.
e Valve body components.

7A1-44 AUTOMATIC TRANSMISSION ON-VEHICLE SERVICE
Inspect
e Refer to the Unit Repair Section for
disassembly and inspection procedures.
Install or Connect
1. Valve body, spacer, check balls and bolts as
outlined in the Unit Repair Section.
2. New
"0" ring
seal and oil filter.
- Coat "0" ring seal with petrolatum.
3. New gasket, oil pan and bolts.
- 20 N.m (15 lbs. ft.)
4. Lower car.
5. Fill
transmission to proper level with Dexron
I1
fluid or equivalent, see Section 7A.
Adjust
e T.V. cable, see Figs. 5 thru 7.
REAR OIL SEAL
Remove or Disconnect
Tool Required:
J 21426 Seal Installer
1. Raise car and suitably support, see Section OA.
2. Propeller shaft, see Section 4A.
3. Pry out lip seal with a suitable tool.
Install or Connect
I. Coat outer casing of new lip oil seal with
non-hardening sealer and tap in place with
J
2 1426.
2. Propeller
shaft, see Section 4A.
3. Lower car.
Adjust
e Transmission fluid level.
- Dexron 11 Automatic Transmission Fluid
OIL COOLER LINES AND/OR FITTINGS
Figs. 13 and 14
If replacement of transmission cooler lines is
required, use only double wrapped and brazed steel
tubing meeting
GM specification 123M or equivalent.
Tubing should be double flared.
NOTICE: Allow sufficient clearance around
cooler lines to prevent damage or wear which may
cause fluid loss.
OIL COOLER FLUSHING
Tools Required:
J 35944 Cooler Flushing Tool
J 35944-20 Flushing Solution
Water Supply
Air Supply (with water and oil fil-
ter)
Oil Drain Container
5 Gallon Pail
1. Remove the fill cap on J 35944 and fill with .6
liters (20-21 ounces) of J 35944-20 flushing
solution.
@ Do not over fill
@ Follow manufacture's suggested proce-
dures for solution handling.
Replace cap on
J 35944 and pressurize it to 550-
700
kPa (80-100 psi).
Connect
J 35944 to the transaxle end of the oil
cooler pipe that feeds the BOTTOM fitting of
the oil cooler.
Connect the discharge hose to the TOP oil
cooler pipe and clip the discharge hose to the oil
drain container.
With the water valve on
J 35944 in the "off'
position, connect the water supply to the tool.
Turn the water valve off.
Flush the transaxle fluid by opening the water
valve to the "on" position for about 10 seconds.
Important
@ If water does not flow thru the cooler the
system is completely plugged. Do not
complete the flushing procedure. Replace
the cooler
and/or the cooler pipes as
required.
8. Close the water valve and clip the discharge
hose to the 5 gallon pail. Cover the pail with a
shop towel to prevent splash.
9. Turn the water valve to
the
"on" positon and
depress the trigger to mix flushing solution into
the water flow. Use the bail clip provided to
hold the trigger down.
10. Flush the
cooler with water and solution for 2
minutes. During this flush, attach the air supply
to the air valve located on the tool, for 3 to 5
seconds every 15-20 seconds. This will create a
surging action to ensure complete cleaning.
11. Release the trigger and turn the water valve off.
12. Disconnect both hoses from the oil cooler pipes.
13. Reconnect the hoses to the pipes opposite the
initial flush to preform a backflush.
14. Repeat steps 9 and 10
15. Release the trigger and allow water to rinse
for
one minute.
16. Turn the water valve off.
17. Attatch the air supply to the air valve and dry the
system out with air until no moisture is seen
leaving the discharge hose.
18. Connect the Cooler Feed Pipe to the transaxle.
19. Clip the discharge hose to the oil drain con-
tainer.
20. After filling the transaxle with
fluid,
start the
engine and run for 30 seconds. This will remove
any residual
moistrue from the oil cooler. A
minimum of 2 quarts of fluid should flow during
the 30 second period. If fluid flow is sufficient,
check the fluid flow by disconnecting the feed

1. CONNECTOR (TRANSMISSION)
2. 21 N.m (15 LBS. FT.)
3. 27 N.m (20 LBS. FT.)
J10009-7A1-F
Fig. 13 Oil Cooler Pipes - V.I.N. S
1. CONNECTOR (TRANSMISSION)
2.
21 Nm (15 LBS. FT.)
3. 27 Nm (20 LBS. FT.)
J10010-7A1-F
Fig. 14 Oil Cooler Pipes - V.I.N. E, F and 8

7Al-16 AUWBMATIC TWANSMIS810N ON-VEHICLE SERVICE
line at the cooler and observe the flow with the
engine running.
@ Insufficient flow: inspect cooler pipes, fit- 5.
tings and repeat cooler flushing proce-
dure. If the flow is still insufficient,
replace the cooler.
21. Remove the discharge hose and reconnect the
cooler pipe. Adjust fluid level as needed. 7.
8.
9.
TRANSMISSION ASSEMBLY 10.
Figs. 73 tkru 1 7
A pressure test should be performed before
transmission removal to aid in diagnosis.
Tools Required:
J 21366 Torque Converter Holding Fixture
Remove or Disconnect
1. Negative battery cable.
2. Air cleaner.
3. T.V.
cable at throttle lever.
4. Transmission fluid level indicator.
5. Raise
car and suitably support, see Section
OA.
6. Speedometer cable.
7. Shift control cable.
8. Electrical leads at transmission.
9. Flexplate cover.
e Mark flywheel to torque converter.
10. Torque converter bolts.
11. Torque arm, see Section 3D.
12. Propeller shaft, see Section
48.
13. Support transmission.
14. Crossmember and mount bolts.
15. Oil cooler pipes at transmission.
16. T.V. cable at transmission.
17. Transmission to engine bolts.
18. Transmission.
a Install J 21366 and remove transmission.
Clean
Transmission oil cooler and lines
should be Flushed with
J35944 or
equivalent whenever the transmission
has
been removed for overhaul or re-
placement of the torque converter,
pump or case.
Install or Connect
1. Attach transmission jack.
2. Raise transmission.
- Remove J 21 366
3. Transmission to engine bolts.
- 44N.m(35 Ibs. ft.)
4. Crossmember, mount and bolts.
- Crossmember to body.
- 54 N .m (40 lbs. ft.)
- Mount to crossmember.
- 44 W-m (35 lbs. ft.)
- Mount to transmission.
- 54 N-m (40 Ibs. ft.)
Torque converter to flexplate bolts.
- 47 N-m (35 lbs, ft.)
- Align marks made during disassembly,
- Flexplate cover.
Oil cooler lines.
T.V. cable.
Electrical leads at transmission.
Speedometer cable.
Shift control cable.
11. Propeller shaft, see Section 4A.
12. Torque arm, see Section 3D.
13. Lower car.
14.
T.V. cable at throttle lever.
15. Negative battery cable.
16. Air cleaner.
Fig. 15 Converter to Flexplate
Fig.
16 Trans. to Engine

AUTOMATIC TFIANSMISSION ON-VEHICLE SERVICE 7A1-17
Fluid Capacity
@ Pi111 Kcmoval .................. 10 pinls (4.7 1,ilres)
@ Ovcrliaul ..................... 13 pints ( l0.0 I,irrcs)
Recommended Fluid
Dcxroli I1 Auronii~tic 11.ansniission I-'luitl # 105 1x55
@ Shift control cable.
T.V. cable
@ Fluid level
- Dexron I1 Automatic Transmission Fluid
Fig. 17 Transmission Converter Shield

SECTION 7B
5-SPEED 77MM TRANSM
RPO-M39 MK6 AND MBI
CONTENTS
........................... ................... ............................... General Description 7B-1 Gears ... 7B-12 .......................... .............................................. Diagnosis 7B-2 Front and Rear Bearings ..7B-12 ...................... ................................ On Vehicle Service 7B-3 Synchronizer Blocking Rings .7B-12 .................................................. ........................................... Shift Lever 7B-3 Repairs ,7B-12
......................................... ................... Transmission 7B-3 Synchronizer Keys and Springs .7B- 12
....................... ............... Extension Housing Oil Seal 7B-3 Extension
Oil Seal and/or Bushing .7B-13
Speedometer Driven Gear ......................... 7B-6
Drive Gear Bearing Retainer Oil Seal ............ 7B-14
........................................... .................................. Unit Repair 7B-6 Transmission Cover .7B-14
....................... ....................... Disassembly of Transmission 7B-6 Front Counter Shaft Bearing .7B-15 .............................. ......................... Disassembly of Mainshaft .7B- 10 Assembly of Drive Gear .7B- 16 ............................... ........................ Disassembly of Drive Gear ,7B- 1 1 Assembly of Mainshaft 7B- 16 ............................. ............................ Cleaning and Inspection ,7B-11 Assembly of Transmission 7B-17 ........................................ ............................... Transmission Case .7B-11 Specifications .7B-19
....................... .......... .................... Bearing Rollers and Spacers .7B-11 Special Tools ... .7B-20
GENERAL DESCRIPTION
Manual transmissions are identified by (A) the
number of forward gears and
(B) the measured dis-
tance between centerlines of the mainshaft and the
countergear.
The 5-speed 77mm transmission is a fully syn-
chronized unit with blocker ring synchronizers and a
sliding mesh reverse gear. First and second gears have
three-piece synchronizer rings, consisting of steel
inner and outer cones and
a tapered metal ring that is
lined on both sides with friction material similar to
automatic transmission friction plates. The cones are
independent of the gears and can be replaced sepa-
rately. Third and fourth gear blocker rings are more
conventional in appearance, but are also lined with
friction material. The fifth gear blocker ring is brass.
NOTICE: No lubricant other than Dexron I1
#I051855 or equivalent should be used in this
transmission. Other lubricants or additives may
damage the blocker ring friction material or its
adhesive.
The mainshaft and the countershaft are sup-
ported on tapered roller bearings and must be
shimmed for proper end play. First through fourth
speed mainshaft gears ride on caged roller bearings.
An aluminum transmission case houses the various gears and bearings. The gearshift lever assembly is
floor-mounted and is located on top of the extension
housing. The shift mechanism does not require adjust-
ment and can be serviced independently of the
transmission.

Shift rail binding Check
for mispositioned selector
arm roll pin, loose cover bolts,
worn shift rail bores, worn shift
rail, distorted oil seal, or extension
housing not aligned with case.
Repair as necessary.
Internal bind in transmission Remove,
disassemble and inspect
caused by shift forks, selector transmission. Replace worn or
plates, or synchronizer assemblies damaged components
as necessary.
Incorrect lubricant Drain
and refill transmission.
GEAR CLASH WHEN
Clutch travel incorrect Refcr to clutch \cct~on SHIFTING FROM ONE GEAR TO Lubricant level
low or incorrect Drain
and refill transmission and
check for lubricant leaks if level
was low. Repair as necessary.
Gearshift components, or Remove,
disassemble and inspect
synchronizer assemblies worn transmission. Replace worn or
damaged components as necessary.
TRANSMLSSION Drain and refill transmission. If lubricant level was low, check
for leaks and repair as necessary.
Check and correct bolt torque
as necessary.
Clutch housing bore to
cranksahft pilot Check
alignment and adjust as necessary
Gearshift mechanism, trans- Remove,
disassemble and inspect
mission gears, or bearing
com- transmission. Replace worn or
ponents worn or damaged damaged components
as necessary.
JUMPS OUT OF GEAR Offset
lever plastic insert worn or Remove
gearshift lever and check
for loose offset lever or worn
insert. Repair or replace as
necessary.
Gearshift mechanism, shift Remove,
disassemble and inspect
forks, selector plates, interlock transmission
cover assembly.
plate, selector arm, shift rail, Replace
worn or damaged compo
- springs or shift cover worn or nents as necessary.
Gear teeth worn or tapered, Remove,
disassemble and inspect
synchronizer assemblies worn transmission. Replace worn or
or damaged, excessive end play damaged components
7s necessary.
caused by worn thrust washers
WILL NOT SHIFT
or output shaft gears
INTO
ONE GEAR
Gearshift selector plates, inter-
lock plate, or selector arm, worn, transmission cover assembly.
Repail damaged, or incorrectly assembled or
replace components as necessary.
Synchronizer sleeves or hubs, Remove,
disassemble and inspect
damaged or worn transmission. Replace worn or
LOCKED
IN ONE damaged components.
GEAR - CAN NOT
BE SHIFTED OUT Shift rail(s) worn
or broken, shifter
fork bent or worn
Disassemble transmission. Re
-
Figure '1 Diagnosis

5-SPEED 77MM TRANSMISSION 7B-3
ON-VEHICLE SERVICE
SHlR CONTROL LEVER
Remove or Disconnect
1. Screws from transmission shift lever boot
retainer and slide boot up lever.
2. Shift lever attaching bolts at transmission and
remove lever.
NOTICE: The upper lever is no longer threaded
to the lower lever. The levers are bonded
together. Separation of the levers will damage the
shifter requiring replacement of the shifter
assembly.
Install or Conned
1. Shift lever and attaching bolts to transmission.
2. Shift lever boot, boot retainer and retainer
screws to transmission.
~ibure 2
Remove or Disconnect
1. Negative cable at battery.
2. Shift lever attaching bolts from transmission.
NOTICE: The upper lever is no longer threaded
to the lower lever. The levers are bonded
together. Separation of the levers will damage the
shifter requiring replacement of the shifter
assembly.
3. Raise vehicle.
4. Torque arm. (See Section 3D)
5. Propeller shaft. (See Section 4A)
6. Speedometer cable at transmission.
7. Electrical connection at transmission.
8. Support transmission with suitable jack stand.
9. Transmission mount attaching bolts.
10. Catalytic converter hanger.
Figure 2 Transmission To Engine Attachment
11. Crossmember attaching bolts.
12. Crossmember.
13. Dust cover bolts.
14. Transmission to engine attaching bolts.
15. Transmission.
NOTICE: Inspection of clutch components
should be made after transmission removal. If the
clutch requires repair, see section 7C before
transmission is reinstalled.
Install or Connect
Transmission.
Transmission to engine attaching bolts.
Dust cover bolts.
Crossmember
Crossmember attaching bolts.
Catalytic converter hanger.
Transmission mount attaching bolts.
Remove jack stand supporting transmission.
Electrical connection to transmission. Speedometer cable to transmission.
Propeller shaft. (See Section
4A)
Torque arm. (See Section 3D)
Lower vehicle.
Shift lever attaching bolts to transmission.
Negative cable to battery.
EXTENSlOM HOUSING OIL SEAL
Figure 3
Remove or Disconnect
1 . Raise vehicle.
2. Propeller shaft. (See Section 4A)
3. Pry seal out of extension housing using a
screwdriver.
Figure 3 Extension Housing Oil Seal