Clutch Wear:

Owners of some 1984-87 Fieros equipped with manual transmissions may comment of clutch slippage, separation of facing from the driven disc, gear clash, excessive shift effort, or excessive clutch pedal effort. Prior to replacing a clutch assembly in any of these vehicles, use all four (4) of the following cause and action statements to locate and repair the reasons for the clutch wear.

FIGURE 1:

Reference Figure #1.

1. Cause: Clutch release difficult, due to excessive clutch pedal deflection and/or bent clutch pedal "standoff" bracket.

Action: Using the procedure below, install the following new components and discard the clutch pedal return spring, spring bushing, and push rod pin washers which are not used with the replacement system.

PART DESCRIPTION PART NUMBER

Steel Clutch Pedal (1984-86 ONLY) 10066423
Master Cylinder Push Rod (1984-85 ONLY) 10126424
Master Cylinder Push Rod (1986 ONLY) 10126423
Retainer Clip 10040797
Lubriplate or equivalent 1052196
Castrol Fluid 12345347

Parts are currently available from GMSPO.

Procedure:

A. Remove clutch master cylinder push rod from clutch pedal.

B. Remove neutral start switch.

C. Remove the rubber bumper (sleeve) from the clutch pedal return stop and discard.

D. Remove nut from pedal pivot bolt.

E. Slide pivot bolt half way out, loosen two (2) pivot bracket bolts, and remove clutch pedal.

F. Disconnect hydraulic line from master cylinder.

G. Remove master cylinder mounting bolts and remove master cylinder from front of dash.

H. Remove the boot, snap ring and push rod from the master cylinder.

I. Install the new push rod and snap ring in the master cylinder (lubricate the installed end of the push rod). Reattach the boot to the master cylinder.

J. Bench bleed the master cylinder, using Castrol Fluid as replacement fluid.

K. Reinstall the master cylinder to front of dash and reattach hydraulic line.

L. Install new pedal assembly and apply liberal amount of Lubriplate lubricant to inner and outer diameters of pedal bushings and spacer.

M. Torque pivot bolt nut, and also torque pivot bracket bolts.

N. Apply Lubriplate lubricant to the bushing in master cylinder push rod, and on pedal push rod pin.

O. Attach push rod to pedal and secure with retainer clip, per Figure 1. DO NOT USE ANY WASHERS.

P. Bleed the system using Castrol fluid as replacement fluid. Power bleeding is acceptable.

Q. Install neutral start switch.

NOTICE: NEUTRAL START SWITCH WILL SELF-ADJUST ON INITIAL DEPRESSION OF CLUTCH PEDAL (RATCHETING NOISE IS NORMAL).

R. Adjust cruise control dump switch per section 9B-8 of the 1988 Fiero Service Manual.

Warranty Information

Labor Operation: T1358

Labor Time: 1.3 Hours

2. Cause: Clutch release difficult, due to clutch fork lever cracking or excessive deflection.

Action: Install new cast iron clutch fork lever in place of the stamped steel lever. Use the following part numbers:

APPLICATION PART NUMBER

1984 4 cyl., 4-speed 10054118
1985-86 6 cyl., 4-speed 10054119
1985-86 4 cyl., 5-speed 10054300
Warranty Information

Labor Operation: K0280

Labor Time: Use appropriate labor time for model year.

3. Cause: Partial clutch disengagement due to interference between the pedal and pedal return stop and/or misadjusted cruise control dump switch. The interference restricts the pedal from returning to its fully engaged position, which retains pressure in the hydraulic system.

NOTICE: THE PEDAL RETURN STOP CONDITION WAS CORRECTED IN PRODUCTION (ON VEHICLES BUILT AFTER VIN GP220697) BY REMOVING THE RUBBER BUMPER (SLEEVE) FROM THE PEDAL SUPPORT ASSEMBLY.

Action: Same as #1.

4. Cause: Insufficient clutch release, due to air in hydraulic system lines.

Action: Bleed hydraulic system, per Section 7C of the Fiero Service Manual. Power bleeding is also acceptable. Use Castrol Fluid as replacement fluid.

Warranty Information

Labor Operation: K0040

Labor Time: .5 Hours

IMPORTANT: When replacing the clutch assembly, inspect the clutch fork shaft for freedom of movement. If there is any restriction in movement, replace the fork shaft bushings per Section 7C of the Fiero Service Manual.