Service Procedure
A. If the transmission is inoperative, submit a campaign claim for inspection only and then follow the transaxle exchange procedure outlined in Service Bulletin 86-7-30.B. If the transmission is operational, refer to the 1987 Fiero Preliminary Service Manual Supplement, Section 7B3, for transaxle removal and installation and shift cable adjustment instructions.
FIGURE 1 - HOLDER COVER:
NOTICE
The detent holder cover (fig. 1) is removed by punching a hole in the center and prying the cover out. Drive the pry bar through the cover at an angle to avoid damaging the shift shafts under the cover. Do not drive the pry bar through the cover any farther than necessary.
1. With transaxle removed from vehicle, use a pry bar to puncture the detent holder cover in the middle and pry it out of the clutch housing using block of wood for leverage (fig. 1).
FIGURE 2 - FIRST GEAR POSITION:
FIGURE 3 - SHIFT SHAFT:
2. Shift the transaxle to first gear (fig. 2). Note: The 1st/2nd shift shaft should not be in the up position, "higher than the 3rd/4th and reverse shift shafts". Visually check to be sure the interlock pin is in place in the 1st/2nd shift shaft (fig. 3). If the pin is missing, contact Pontiac Technical Assistance for disposition of the transaxle.
FIGURE 4 - NEUTRAL POSITION:
3. Shift the transaxle to neutral (fig. 4). The 1st/2nd, 3rd/4th and reverse shift shafts should now be the same height. Also, the input shaft should turn freely.
FIGURE 5 - BOLT "A" REMOVAL:
NOTICE: When performing the following steps, never remove more than one detent holder bolt at a time (fig. 5).
4. Place a screwdriver in the breather hole and remove bolt A. (DO NOT REMOVE BOLT B AT THIS TIME). Discard the bolt (fig. 5). Note: Screwdriver restricts detent holder assembly from sliding away from shafts and prevents loss of detent balls into case.
FIGURE 6 - DETENT HOLDER ASSEMBLY:
5. Place the new interlock plate on the detent holder assembly. Screw in a new 9 mm x 32 mm bolt 3 to 4 turns (fig. 6).
-INTERLOCK PLATE:
6. Remove bolt B and discard the bolt. Swing the interlock plate into place on the detent holder assembly. Pry the detent holder assembly into place with a screwdriver and install the second new 9 m x 32 mm bolt approximately 4 turns (fig. 7).
FIGURE 8 - CARDBOARD ALIGNMENT SLEEVE:
7. Place the cardboard alignment sleeve over the 1st/2nd shift shaft (fig. 8). Push interlock plate in contact with alignment sleeve.
8. Tighten both 9 mm x 32 mm bolts to (84 in.lbs). Remove the alignment sleeve and screwdrivers.
FIGURE 9 - SHIFT SHAFT:
9. Prior to the installation of the detent holder cover, inspect the 1st/2nd shift shaft, it must still be the same height as the 3rd/4th and reverse shift shafts (fig. 9). Shift the transaxle through each gear checking for proper operation. If the transaxle shifts correctly return to the neutral position and continue to Step 11. If the shift mechanism is locked, the 1st/2nd shift shaft has slipped down during installation of the interlock plate and the shaft must be pulled up.
10. To pull the 1st/2nd shaft up, reinstall screwdriver in vent hole. Loosen bolt A and remove bolt B. Pull shaft up using pliers. Swing interlock plate into position, pry detent holder assembly into place with screwdriver and loosely install bolt B. Return to Step 7.
FIGURE 1 - HOLDER COVER:
11. Tap the detent holder cover (fig. 1) into the bore until seated.
FIGURE 10 - THIRD GEAR:
12. Shift the transaxle into third gear (fig. 10).
13. Install transaxle in vehicle and adjust shift cables per the 1987 Fiero Preliminary Service Manual supplement.
14. Install Campaign Identification Label.
CAMPAIGN IDENTIFICATION LABEL:
Each vehicle modified in accordance with the instructions outlined in this Product Campaign Bulletin will require a "Campaign Identification Label". Each label provides a space to include the campaign number, the five digit dealer code of the dealer performing the campaign service, and the date vehicle was campaigned. This information may be inserted with a typewriter or ballpoint pen. Install the label only on a clean, dry surface of the radiator baffle where it is readily visible. Close hood. (Additional campaign labels are available on stationery order as Form 7901-709.)
CLAIM INFORMATION
A separate repair order must be used for each vehicle. A completed warranty claim is to be kept as a permanent record of completion.
DEALERS SHOULD SUBMIT WARRANTY CLAIMS FOR CREDIT IN THEIR NORMAL MANNER WHEN THEY PERFORM THE SERVICE AS FOLLOWS:
Other*
Failure Labor Labor Labor
Operation Code Operation Hours Hours
Inoperative trans- 96 V3640 .2 .1
mission inspection only
Install detent 96 V3641 6.0 .1
holder interlock spacer plate
*In addition dealerships will receive 0.1 hours credit for dealer administrative services associated with this campaign. The 0.1 hours allowance is to be entered in the "Other Labor Hours" field with each campaign repair listed for credit. This entry will not require authorization.
FAILURE CODE 96 MUST BE USED WITH THE LABOR OPERATION.
Parts will be supplied to dealers by Pontiac and therefore no part number will be listed on the repair order or warranty claim. An allowance of $8.08 should be entered as a net items figure in the sublet column of the warranty claim to receive proper credit. The $8.08 figure represents a 30% parts handling allowance of $4.28 as well as a dealer material allowance of $3.80.
Dealers will be credited via Warranty Document or Terminal Transmission, whichever is their normal method of submission for payment. Claims must contain all information required and should list the labor operation as outlined.
RECORDING COMPLETION
Repairs submitted for vehicles not involved in the campaign will not be paid.
Campaign completion will be recorded from "PROPERLY COMPLETED AND PAID WARRANTY CLAIMS". Owners are being asked to present the owner reply card for identification to their dealer at the time they bring in their vehicle to have the campaign performed.