At long last, I have both CV axles installed and some $500 later! Man, what trip. My extreme measure was to cut the shaft on one axle (outer knuckle area on the Fiero manual axle). Then drill out the shaft. That took two days and over a $100 in hardened steel drill bits. I ended up rebuilding the passenger side axle. Pretty much the same for the driver side. More or less..... ended up using a driver side CV axle I had from my 4T440 transmission swap when I discovered the 2002 GM mini-van CV axle that I have purchased for the driver side build has a different spline pitch and axle shaft diameter. It fit like a glove. I used the Tri-cup from a 4T65e transmission.

Passenger side CV axle:



Driver side CV axle:



I have completed plumbing the carbon filter canister.

Now in the process of building the exhaust system. That should be real fun.....

Later I will provide information on my CV axle built with part numbers. That will give anyone the opportunity to follow the build and use the part numbers.

Currently I am fitting the exhaust system (muffler & piping) to the cradle so I will have reference points for the exhaust build from engine to muffler.

Still waiting on parts: coil-over springs and sleeves.

I am still at it trying to complete this project. The CV axle build ate my lunch.

I have added an engine oil temperature sensor to monitor the engine.



I also added an engine water temperature sensor (Fiero OEM) to provide information to my digital instrument cluster.



The coil over sleeves have arrived, however they did not slide over the struts. So, they are currently at my son's shop being machined. Hopefully the coil over springs will arrive in the next couple of days.

I have been working on attempting to sort the exhaust system. I am going with Stainless steel components, piping, connectors, muffler and catalytic converter. He is a photo of the mock up.....


I need to drop the gas tank before I can install the engine/cradle assembly. I am dropping the gas tank to check out the fuel level sender.

[This message has been edited by Cajun (edited 10-10-2025).]

Cajun what digital instrument cluster will you be using?

My CV axle build information:

For the Passenger Side:
1. For the outer CV joint - the part that couples to the wheel bearing hub - 84-88 Fiero Manuel CV outer joint
2. Concerning the inner CV joint portion and CV axle inner shaft from a late 90's to early 00's GM W-body vehicle with the OD transmission; I used parts from a 2001 Lumina; P/N NCV 19542 from Rock Auto
3. Basically, one has to separate the Fiero CV axle for the outer joint (knuckle); P/N GM 8071
4. The inner CV joint and axle is from a W-body vehicle
5. For my build I was not able to separate the outer joint from the axle. I ended up cutting the axle near the knuckle and drilling out the shaft to be able to use the knuckle for the build
6. I used the inner tri-pot (transmission side) from a 4T65e transmission

For the Driver Side:
1. I attempted to use the suggested CV axle build but was unsuccessful; again, had issues with separating the outer knuckle from the axle.
2. When I was able to separate the outer knuckle from the axle only to find out the spline count and angel was wrong for my build.
3. I ended up using the Drive side CV axle from my previous 4T440 build.
4. The difference is that I utilized the inner tri-pot from a 4T54e transmission. I fit like a glove and way less hassle.
5. The driver side CV axle is from a driver side CV axle from a 1990 Pontiac 6000


On a side note, my coil over springs should be in Wednesday.

The coil over springs have arrived. Unfortunately, the other parts, i.e. Bumper, dust cover & thrust washers are not due to arrive until Wednesday at the earliest.