1987 Pontiac Fiero Base, AutomaticFACTORY OEM SERVICE PROCEDURE

Transaxle Reassembly

  1. Assemble input and output shaft assemblies. Install 1st-2nd gear shift rail. Install interlock pin. Retain pin using petroleum jelly. Install 3rd-4th gear shift rail. See Fig 1 . Install 5th gear shift rail. Install reverse gear shift rail. Install shift gate and disengage roller.
  2. Position gear cluster/shift rail assembly on Assembly Pallet (J-36182-1). Align shift rail and shaft pilots to pallet. Install transaxle case. Align bearing bores in case with shaft pilots. Using Bearing Installer (J-35824), press in NEW input and output shaft bearings. See Figure .
  3. Ensure both bearings are seated properly. Remove transaxle from Assembly Pallet (J-36182-1). Shift transaxle into 4th and reverse gears. Using Hex Bolt Socket (J-36031), install NEW input and output shaft bearing retainer. See Figure . Tighten bolt to specification. See TORQUE SPECIFICATIONS  .
  4. Shift transaxle to Neutral position. Install reverse lever, shift lever and 3rd-4th bias spring. Install shift shaft pins and rollers to shift shaft. Use petroleum jelly to retain rollers. Lightly tap shift shaft assembly into place. Align hole in shaft with hole in shift lever. Install NEW lever retainer pin until pin is flush with surface of shift lever. See Fig 2 .
  5. Apply sealant to inside of bolt hole pattern on gear case flange. Install differential assembly. Install output bearing with small diameter of bearing cage facing clutch housing. Install magnet into bottom of case. Install case bolts and tighten them to specification. See TORQUE SPECIFICATIONS  .
  6. Install shim previously selected in OUTPUT SHAFT SUPPORT BEARING SELECTIVE SHIM PROCEDURE  . Apply sealant to bolt hole pattern on inside of plate, and install transaxle case end plate. Install thread sealant to end plate bolt threads and install bolts.
  7. Position shift rails so that 5th gear shift rail is 1/4 inch below other shift rails. Shift rails must be in Neutral position. Install reverse bushing. See Figure . Assemble interlock pins and springs into bores in detent holder. Retain components with petroleum jelly.
  8. Install detent holder and spring assembly with detent ball for reverse shift rail. Using a screw driver, install detent balls. Position holder until bolt holes and threads are aligned. Install bolts and tighten them to specification. See TORQUE SPECIFICATIONS  .
  9. Ensure shift rails are in correct detent positions. Install NEW detent cover. Tap cover until seated in bore. Ensure cover is flush with bore. Install clutch release bearing. Install high temperature grease to inside bore of bearing.
  10. Install shift shaft detent inner spring seat, 5th-reverse bias spring and outer spring seat. Install Loctite on bolt threads and install bolt. Apply a thin coat of sealant to mating surface of case bore, and install NEW shift shaft cover. Install snap ring. See Figure .
    CAUTION: Ensure shift shaft cover top is not caved in. Caved-in cover may cause a hard shift into 1-2 gate by not allowing full travel of shift shaft.
  11. Install selector lever bracket and bolts. Use sealant on bolt threads. Install shift shaft collar and NEW spring pin. Apply a thin coat of high temperature grease to slot in collar. Install selector lever and NEW pivot pin. Install shift lever, washer and nut. Apply Loctite to shift shaft threads.
  12. DO NOT  allow lever to move during installation of nut. Hold shift lever at shift cable mounting stud. Install fluid level indicator. Coat NEW seal with transaxle fluid and install seal on speedometer signal assembly. Install speedometer signal assembly and bolt. Tighten bolt to specification. See TORQUE SPECIFICATIONS  .
Fig 1: Identifying Gear Clusters & Shift Rail Assemblies
G92J12558Courtesy of GENERAL MOTORS CORP.
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