CAMPAIGN MUNCLE 5-SPEED TRANS. STICKS IN FIRST GEAR

MODELS AFFECTED: 1986 PONTIAC FIERO GT W/2.8L V6 ENGINE AND 5-SPEED TRANSMISSION

General Motors has determined that some 1986 Pontiac Fiero GT model vehicles equipped with 2.8L V6 engine and 5-speed manual transmission may experience a condition whereby the interlock pin for the 1-2 shift rail may partially come out of the detent block bore and prevent shifting of the transaxle out of first gear.

To prevent this condition from occurring, an interlock spacer plate will be added to the detent holder to assure proper retention of the interlock pin.

VEHICLES INVOLVED

Involved are certain 1986 Pontiac Fiero GT Models equiped with 2.8L V6 engine and 5-speed manual transmission and built within the following vehicle breakpoints:

Assembly Beginning Up To & Incl. Model Plant VIN VIN ----- -------- --------- -------------

1986 Pontiac GP200031 GP283971

Involved vehicles have been identified by Vehicle Identification Number computer listings. Computer listings contain the complete Vehicle Identification Number, owner name and address data, and are furnished to the involved dealers with the campaign bulletin. Owner name and address data furnished will enable dealers to follow up with owners involved in this campaign.

These listings may contain owner names and addresses obtained from State Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states. Accordingly, you are urged to limit the use of this listing to the follow up necessary to complete this campaign. Any dealer not receiving a computer listing with the campaign bulletin was not shipped any involved vehicles.

OWNER NOTIFICATION

Owners will be notified of this campaign on their vehicles by Pontiac Division (see copy of Owner Letter included with this bulletin).

DEALER CAMPAIGN RESPONSIBILITY

Dealers are to service all vehicles subject to this campaign at no charge to owners, regardless of mileage, age of vehicle, or ownership, from this time forward.

Whenever a vehicle subject to this campaign is taken into your new or used vehicle inventory, or it is in your dealership for service in the future, you should take the steps necessary to be sure the campaign correction has been made before reselling or releasing the vehicle.

Owners of vehicles recently sold from your new vehicle inventory are to be contacted by the dealer, and arrangements made to make the required modification according to instructions contained in this bulletin.

PARTS INFORMATION

Parts required to complete this modification will be shipped directly to dealers on a no charge basis. Additional parts may be obtained by contacting your zone office.

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 instalation and shift cable adjustment instructions.

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).

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 lst/2nd shift shaft (fig. 3). If the pin is missing, contact Pontiac Technical Assistance for disposition of the transaxle.

3. Shift the transaxle to neutral (fig. 4). The lst/2nd, 3rd/4th and reverse shift shafts should now be the same height. Also, the input shaft should turn freely.

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

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).

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 mm x 32 mm bolt approximately 4 turns (fig. 7).

7. Place the cardboard alignment sleeve over the lst/2nd shift shaft (fig. 8). Push interlock plate in contact with alignment sleeve.

8. Tighten both 9 mm x 32 mm bolts to (84 lb. in.). Remove the alignment sleeve and screwdrivers.

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 lst/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.

11. Tap the detent holder cover (fig. 1) into the bore until seated.

12. Shift the transaxle into third gear (fig. 10).

13. Install transaxle in vehicle and adjust shift cab-les 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.

General Motors bulletins are intended for use by professional technicians, not a "do-it-yourselfer". They are written to inform those technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions and know-how to do a job properly and safely. If a condition is described, do not assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See a General Motors dealer servicing your brand of General Motors vehicle for information on whether your vehicle may benefit from the information.