Before You Begin:
* Safety First: Disconnect the negative battery terminal. Support the vehicle securely on jack stands. Use appropriate safety glasses and gloves.
* Repair Manual: Obtain a factory service manual or a reputable aftermarket repair manual specifically for your year and model Fiero. This will provide detailed instructions, torque specifications, and diagrams.
* Tools: You'll need a wide array of tools including socket sets (metric), wrenches, torque wrench, clutch alignment tool, transmission jack, pry bars, and possibly a flywheel grinder/surfacing tool.
* Parts: Source a new clutch kit (clutch disc, pressure plate, throw-out bearing), pilot bearing (if necessary), and any other parts you find worn or damaged during disassembly.
General Steps (This is a simplified overview; consult your manual):
1. Preparation: Drain the transmission fluid. Disconnect the driveshaft. Remove the exhaust system components that interfere with access to the transmission.
2. Transmission Removal: This is the most challenging part. You'll need to disconnect the linkage, various electrical connections, and possibly the starter motor. Then, carefully support the transmission and remove the bolts attaching it to the engine. A transmission jack is highly recommended.
3. Clutch Assembly Removal: Once the transmission is removed, you can access the clutch assembly. Remove the pressure plate bolts, carefully remove the pressure plate, and then the clutch disc. Replace the pilot bearing (if necessary). Inspect the flywheel for wear; it may need to be resurfaced.
4. Installation: Install the new pilot bearing (if replaced). Using a clutch alignment tool, carefully install the new clutch disc, making sure it's properly seated on the transmission input shaft. Install the new pressure plate, tightening the bolts to the manufacturer's specified torque.
5. Transmission Reinstallation: Carefully reinstall the transmission, ensuring it's properly aligned. Reconnect all linkages, electrical connections, and the driveshaft.
6. Refill and Bleed: Refill the transmission with the correct type and amount of fluid. Bleed the clutch hydraulic system (if applicable) to remove air bubbles.
7. Testing: Carefully start the engine and test the clutch operation. Check for leaks and unusual noises.
Important Considerations:
* Flywheel Resurfacing: A worn flywheel will prevent proper clutch engagement. It may need to be resurfaced on a lathe to ensure a flat surface.
* Hydraulic System: The clutch hydraulic system might need bleeding after reinstallation.
* Torque Specifications: Adhering to the correct torque specifications for all bolts is crucial to prevent damage.
* Alignment Tool: Using a clutch alignment tool is essential to prevent damage to the clutch disc and transmission input shaft.
Again, this is a highly simplified overview. Do not attempt this repair without consulting a detailed repair manual specific to your Pontiac Fiero. If you're not comfortable with this level of automotive repair, it's best to have a qualified mechanic perform the work. Improper repair can lead to significant damage and potentially dangerous situations.
