drain bolt OPEL GT-R 1973 User Guide

78.241973 OPEL SERVICE MANUAL
Removing Shifter Shaft
1. Remove cotter pins that secure each end of shifter
shaft. See Figure
7B-20.7&20
Figure 78.20 Cotter Pin Locations on Shifter Shaft
2. Remove shifter shaft with washer and spring
washer at each end.
Removing Selector Lever
1. With punch, drive out pin securing selector lever
to transmission case extension bolt. See Figure 7B-
21.
Figure
78-21 Pin and Bracket Securing Selector
Lever to Intermediate Shaft and Rear Bearing
Retainer2. Remove the two (2) bolts and spring washers from
the transmission case extension housing which se-
cure selector lever bracket. See Figure 7B-2 1.
3. Remove selector lever and bracket. Selector lever
will just slip off selector ring.
4. Remove lock nut and selector ring.
5. Remove transmission case extension bolt. See Fig-
ure 7B-21.Removing Transmission Case Cover
1. Remove ten (10) transmission case cover bolts,
cover, and gasket.
2. Invert transmission to drain oil.
Removing Countergear
1. Remove remaining three transmission case exten-
sion housing to case attaching bolts and spring wash-
ers.2. Turn transmission case extension housing until
gear unit countershaft is exposed. See Figure 7B-22.
Figure
78-22 Position of Rear Bearing So
Countergear Can Be Removed
3. From the front of the transmission, using Special
Tool J-2291 1, drive out shaft. Ensure that lock ball
is not lost. See Figure 7B-23.
Figure
78-23 Removing Countergear Shaft

7C- 821973 OPEL SERVICE MANUALAUTOMATIC TRANSMISSION TROUBLE
DIAGNOSIS CHART
Condition
CEllE.e
Concerns Transmission Oil1. Low oil level.a) Oil coming out of oil tiller tube.
b) External oil leak.
c) Failed vacuum modulator.
2. Oil coming out of oil filler
tube.a) Oil level too high.
b) Coolant in transmission oil.
c) External vent clogged with mud.
d) Leak in oil pump suction circuit.
3. External oil leaks in the area
of the torque converter housing.a) Leaking torque converter.
b) Converter housing seal.
c) Sealing washers under converter
housing to case bolts.
d) Sealing washers under converter
housing to pump bolts.
e) Converter housing to case seal.
fj Loose attaching bolts on front of
transmission.
4. External oil leaks in the area
of transmission case and extension.a) Shifter shaft seal.
b) Extension seal.
c) Oil pan gasket.
d) Extension to case gasket.
e) Vacuum modulator gasket.
f) Drain plug gasket.
g) Cooler line fittings.
h) Oil tiller tube seal ring.
i) Detent cable seal ring.
j) Line pressure gauge connection.
5. Low oil pressure.a) Low oil level.
b) Clogged suction screen.
c) Leak in oil pump suction circuit.
d) Leak in oil pressure circuit.
e) Priming valve stuck.
t) Pressure regulator valve malfunction.
g) Sealing ball in valve body dropped out.
6. High oil pressure.a) Modulator vacuum line leaky orinteruupted.
b) Failed vacuum modulator.
c) Leak in any part of engine or
accessory vacuum system.
d) Pressure regulator valve malfunction.
7. Excessrive smoke coming from
exhaust.a) Failed vacuum modulator.
b) Oil from vent valve or leak on hot
exhaust pipe.

7C. 941973 OPEL SERVICE MANUAL
7. Drive out retaining pin and shaft and remove se-
lector detent. See Figure 7C-93.Figure
7C-93Figure
7C-94 - Exploded View of Selector Lever
8. To replace bowden cable in selector lever, knock
off selector handle, remove screws from clamping
piece and pull knob.
9. Remove pull knob and bowden cable, taking care
not to lose lock bolt bushing, thrust springs, ‘and
washer.
10. Place thrust spring, bushing, washer, and thrust
spring onto new bowden cable, in that order, and
insert cable into selector lever.
1 I. Slide pull onto selector lever and clamping piece
onto cable.
12. Heat up new selector lever handle in water to 176
degrees F. and push onto selector lever.
13. Set dimension between pull knob and selector
lever handle at
.4 inch and tighten set screws.
14. Lubricate selector lever detent and shaft. Install
detent, align selector lever with support, install shaft,
and drive in new retaining pin.
15. Install assembly to support housing and install
intermediate selector lever.
16. Install assembly to vehicle and install neutral
start switch.
17. Install console lights and cigar lighter connec-
tions to console and install console to vehicle.
18. Lubricate and connect selector rod to intermedi-
ate selector lever and adjust according to Figure 7C-
198.
MAJOR REPAIRREMOVAL AND INSTALLATION OF AUTOMATIC
TRANSMISSION
Removal
- Opel 1900 and Manta
I. Disconnect battery.
2. Remove dipstick.
3. Remove screws from fan shroud.
4. Remove 2 upper starter bolts.
5. Raise car and provide support for front and rear
and drain oil.
6. Remove bolts from engine support brackets, both
sides. Let brackets hang by front bolts. See Figure7c-105.
7. Remove flywheel cover pan.
8. Remove exhaust pipe from manifold and unhook
rubber tailpipe suspension.
9. Remove drive shaft. Do not misplace thrust spring
in spline.
10. Disconnect cooler lines at flexible hoses.
II. Detach both stabilizer supports from
crossmem-ber to body supports and loosen stabilizer bolts in
lower control arms. See Figure X-84, Callout “B”,

AUTOMATIC TRANSMISSION 7C-135
becomes necessary to check the fluid level, the trans-
mission may be checked at room temperature (70
degrees F.) as follows:
1. With manual control lever in Park position start
engine. DO NOT RACE ENGINE. Move manual
control lever through each range.
2. lmmediately check fluid level with selector lever
in Park, engine running, and vehicle on LEVEL sur-
face.At this point, when a reading is made, fluid level on
the dipstick should be I/4” below the “ADD” mark.
3. If additional fluid is required add fluid to bring
level to
l/4” below the “ADD” mark on the dip-
stick.If transmission fluid level is correctly established at
70 degrees F. it will appear at the “FULL” mark on
the dipstick when the transmission reaches normal
operating temperature (180 degrees F.) The fluid
level is set
l/4” below the “ADD” mark on the
dipstick to allow for expansion of the fluid which
occurs as transmission temperatures rise to normal
operating temperature of 180 degrees F.
Do not overfill, as foaming and loss of fluid through
the vent pipe might occur as fluid heats up. If fluid
is too low especially when cold, complete loss
of’drive may result which can cause transmission fail-
ure.
2.Draining oilpan and rep/a&g strainer assembly.
(a) Raise car on hoist or p/ace OnJxk stands, and
provide container to collect draining fluid.
(b) Remove oil pan and gasket. Discard gasket.
(c) Drain fluid from oil pan. Clean pan with solvent
and dry thoroughly with clean compressed air.
(d) Remove strainer assembly, strainer gasket and
discard.
(e) Install new oil strainer gasket. Install new strainer
assembly.
(f) Install new gasket on oil pan and install pan.
Tighten attaching bolts to 7-10 lb. ft.
(g) Lower car and add approximately three (3) pints
of transmission fluid through filler tube.
(h) With manual control lever in Park position, start
engine. DO NOT RACE ENGINE. Move manual
control lever through each range.
(i) Immediately check fluid level with selector leverin Park, engine running, and vehicle on LEVEL
sur-
face.(i) Add additional fluid to bring level to
l/4” below
the “ADD” mark on the dipstick. Do not overfill.
3.Adding Fluid to Fill Dry Transmission and Con-
verter Assembly
The fluid capacity of the Opel Three Speed Auto-
matic transmission and converter assembly is ap-
proximately IO-l/2 pints, but correct level is
determined by the mark on the dipstick rather than
by amount added. In cases of transmission overhaul,
when a complete fill is required, including a new
converter proceed as follows:
(a) Add approximately 10-l/2 pints of transmission
fluid through tiller tube.
The converter should be replaced on any major fail-
ure, such as a clutch or gearset, and an excessive
amount of foreign material is indicated in the pan. If
installation of a new converter is not required add
approximately five (5) pints of transmission fluid.
(b) With manual control lever in Park position start
engine and run at 1000 RPM. DO NOT RACE EN-
GINE. Move manual control lever through each
range.
(c) Immediately check fluid level with selector lever
in Park, engine running, and vehicle on LEVEL
sur-
face.(d) Add additional fluid to bring level to
l/4” below
the “ADD” mark on the dipstick. Do not overfill.
Opel Three Speed Automatic Transmission Towing
Instructions
If an Opel equipped with an automatic transmission
must be towed, the following precautions must be
observed:
The car may be towed safely on its rear wheels with
the shift lever in neutral position at speeds of 35 miles
per hour or less under most conditions.
However, the drive shaft must be disconnected or the
car towed on its front wheels if:
a. Tow speeds in excess of 35 mph are necessary.
b. Car must be towed for extended distances (over 50
miles).
c. Transmission is not operating properly.
If car is towed on its front wheels, the steering wheel

9B-60 1973 OPEL SERVICE MANUAL
EVAPORATOR EVAPORATOR
DRAIN HOSE DRAIN HOSE
Figure 96-91 Drain Hose GT
Figure 98.92 Evaporator Mounting Bracket Bolts
Driver Side GT
9. Lift off the mounting bracket and remove the
evaporator assembly from the car.
10. Remove the resistor assembly. See Figure
9B-90.Figure 98-93 Evaporator Mounting Bracket Bolts
Passenger Side
- GT“0” RING-----
OUTLET TUBE
SEAL
9870Figure 98-94 Inlet and Outlet Pipes and O-Rings GT
11. Remove blower case and blower motor attaching
screws and remove assembly.
12. Remove all remaining attaching screws and
remove evaporator assembly. See Figure
9B-95.13. Disconnect expansion valve capillary tube bulb
attached to the outlet pipe of the evaporator. See
Figure 9B-95.
14. Disconnect inlet and outlet ends of expansion

98.94 1973 OPEL SERVICE MANUAL
7. Remove 2 upper evaporator attaching nuts. See
Figures 9B-178 and 9B-181.
Figure 98-181 Location of Upper Evaporator
Attaching Bolt (Right Side)
8. Remove 2 attaching case mpunting bracket to
instrument panel screws. See Figure 9B-182.
Figure SB-182 Evaporator and Blower AssemblyBrackets and Attachments9. From underneath evaporator case, disconnect
two (2) drain hoses.lo. Carefully
PXIIOVS assembly from car. See Figure
9B-184.
11. Disconnect resistor electrical connector and
remove resistor assembly. See Figure
9B-184.12. Remove the blower case and blower motor at-
taching screws and remove assembly. See Figure 9B-
184.Installation
1. Install the blower motor assembly into caseFigure 98-183 Drain Hose
BLOWER MOTOR
Figcre 98.184 Assembly Removed
bracket with the electrical connector side of the mo-
tor to the right side ofthe bracket. Attach the mount-
ing strap.
2. Assemble the case halves and attach the cover
plate.
3. Install the resistor assembly and electrical con-
nector. Install blower motor connector. See Figure
9B-184.4. Install assembly into car carefully guiding
evaporator pipes up through cowl opening. See Fig-
ure 9B-185.
5. Install 2 upper evaporator attaching nuts. See
Figures 9B-178 and 9B-181.
6. Install 2 attaching case mounting bracket to in-
strument panel screws. See Figure 9B-182.

98-102 1973 OPEL SERVICE MANUAL
2. Discharge system. Refer to DISCHARGING
SYSTEM in Refrigerant Components Section.
3. While system is discharging remove the luggage
tray attaching screws and lift out tray. See Figure9B-200.
4. Remove all evaporator cover screws and remove
cover. See Figure
9B-201.Figure
98.202 Evaporator Cover and Luggage Tray5. Remove the electrical plug connector from the
resistor assembly, and unplug blower motor connec-
tion and remove ground wire. See Figure
9B-203.6. From underneath evaporator housing, discon-
nect 2 drain hoses. See Figure 9B-204.
EVAPORATORFigure
98.204 Drain Hose
7. From under car remove 4 nuts securing evapora-
tor mounting bracket to floor. See Figure 9B- 205
and 9B-206.
Figure
98.203 Electrical Connections and Ground
WireFigure 98-205 Evaporator Mounting Bracket Bolts -Driver Side