oil OPEL 1900 1973 Service Manual

MANUAL TRANSMISSION78.2178-12
Figure 78-l 2
Figure
78.132. Knock off gearshift lever button and loosen
threaded pin for Bowden control wire attachment.
See Figure 7B-12.
3. Drive spiral pin and clamping sleeve out of shift
finger tube and stop sleeve. See Figure 7B-14.
4. Remove shift finger and pull Bowden control wire,
together with thrust spring, out of gearshift lever.
5. Oil sliding surface of stop sleeve on shift finger
tube with clutch oil.
6. After installation of thrust spring, attach newBowden control wire first with clamping sleeve.
When doing this, the cutout of stop sleeve in installa-
tion position shows to the left. The spiral pins must
not protrude on either side.
7. Clamp tight Bowden control wire with threaded
pin. Prior to tightening, pull ring must rest on gear-
shift lever tube and clamping block on pull ring.SPIRAL PINS7B-14
Figure 71-14
8. Heat up new gearshift lever knob in boiling water
to 176 degrees F. and push it onto lever tube. Ob-
serve distance A
- .3”, see Figure 7B-15. The gear-
shift lever tube end is provided with transverse
grooves for which reason the old button can no
longer be used.7515
Figure
78-l 5
9. Attach shift finger with spiral pin and install gear-
shift lever.
REPLACING GEARSHIFT LEVER BELLOWS
1. Remove gearshift lever.
2. Knock off gearshift lever button and pull off bel-
lows over pull ring.

78.221973 OPEL SERVICE MANUAL
3. Install new bellows. Adhere to distance A
- 8.07”.
See Figure 7B-I 1.
4. Heat up new gearshift lever knob in boiling water
to 176 degrees F. and push it onto gearshift lever
tube. Adhere to distance A .3”, see Figure
7B-15.The gearshift lever tube end is provided with trans-
verse grooves for which reason the old button cannot
be reused. Install gearshift lever.
REPLACING RUBBER DAMPENING PARTS IN
GEARSHIFT LEVER1. Remove gearshift lever.
2. Knock off gearshift lever button and loosen
threaded pin for Bowden control wire attachment.
3. Remove lower snap ring from gearshift lever tube
and pull tube off shift finger.
4. Take off and replace rubber dampening parts.
5. After installation of tube, tighten Bowden control
wire with threaded pin. Prior to tightening, pull ring
must rest on gearshift lever tube and clamping block
on pull ring. See Figure
7B-15.6. Heat up new gearshift lever knob in boiling water
to 176 degrees F. and push it onto gearshift lever
tube. Adhere to distance A
- .3”, see Figure 7B-15.The gearshift lever tube end is provided with trans-
verse grooves for which reason the old button cannot
be reused.
7. Install gearshift lever.
MAJOR REPAIR
TRANSMISSION REMOVAL1. Remove air cleaner. Remove throttle rod from
carburetor and rear support and disconnect battery.
2. Remove screws from fan shroud.
3. Remove gearshift lever (refer to paragraph on ser-
vicing gearshift lever).
4. Support car with frame or wheel stands in the
front or frame stands in the rear.
5. Loosen front exhaust pipe to manifold flange.
6. Remove clutch cable from fork by pushing fork to
disengage the clutch and unsnap cable from slot.
7. Disconnect both wires from backup lamp switch.8. Disconnect speedometer cable from transmission
case extension housing.
9. Unhook parking brake cable return spring and
remove cable adjusting nut, equalizer, and spacer.
See Figure
7B-16.PARKING BRAKE CABLE
PARKING BRAKE
Figure 78-16 Parking Brake Equalizer and Return
Spring
9. Disconnect drive shaft at central joint and remove
as follows: See Figure
7B-16.a. Disconnect parking brake cable equalizer from
rod.b. Mark the mating parts of U-Joint and the drive
pinion extension shaft flange.
c. Loosen bolt locks and remove bolts or nuts.
d. Work propeller shaft slightly forward, lower rear
end of shaft and slide assembly rearward. Remove
thrust spring.
e. Install a plug in the rear of the transmission to
prevent loss of lubricant.
10. Remove rear engine mount bolts and lower trans-
mission as far as possible.
11. Remove transmission case to clutch housing at-
taching bolts and remove transmission.
INSTALLATION OF TRANSMISSION WITH
ENGINE IN CAR1. Make certain main drive gear splines are clean and
dry. Also, make certain the transmission is in Neu-
tral so that the main drive gear splines may be in-
dexed when making the installation.
2. Install transmission and support weight while in-
stalling transmission case to clutch housing bolts.
3. Install rear engine mount.
4. Install propeller shaft, align, and tighten U-Joint
to pinion flange U-Bolt nuts and torque to 11 lb. ft.

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

MANUAL TRANSMISSION78.254. With Special Tool J-2291 1 inserted, take counter-
shaft gear unit out of transmission case. Remove
both thrust washers.
Removing Selector Shaft and Intermediate Levers
1. Drive out reverse intermediate lever bedding bolt
and remove reverie speed shifter intermediate lever.
See Figure 7B-24.*EVE&E
JNTERME!Figure
78-24 Driving Out Reverse Intermediate LeverPin2. To remove all pins, use a
l/8 inch pin punch. Turn
the selector shaft so that lock pins are in vertical
position. First, drive lock pins out of third and fourth
speed intermediate lever and then out of first and
second speed intermediate lever. See Figure 7B-25.3. Push selector shaft out of case and remove inter-
mediate levers.
4. With screwdriver, pry out selector shaft oil seals
on transmission case.
Removing First and Second Gear Shifter Shaft,
Yoke, and Cam1. Pull out both lock ball plugs using Tool J- 21715
with Slide Hammer J-7004-1. Remove thrust
springs.
2. With transmission in first gear, drive lock pins out
of shifter yokes and shifter shaft cam. See Figure7B-26.
Figure
78-26 Position of Lock Pins for Shifter Forks
and Selector Dogs
3. Turn extension housing until shifter shaft is ex-
posed. From the rear of transmission, drive out first
and second speed shifter shaft. Use suitable brass
drift. See Figure 7B-27.
Figure
78-25 Removing Lock Pins from Selector Shaft
Figure 78.27 Removing Shifter Shafts

78.301973 OPEL SERVICE MANUAL
SHOULDER OR
SHIFTE
.44Figure 78-46 Installing Reverse Shifter Fork
Figure 78.44 Mainshaft Assembly Secured Into Rear
Bearing Retainer by Snap Ring
16. Place front synchronizer spring in the gear shifter
sleeve carrier. Install (3) third and fourth speed shoes
(short design) and gear shifter sleeve over gear shifter
sleeve carrier along with synchronizer cover. Arrows
on shoes point toward rear of mainshaft. Gear shifter
sleeve yoke groove should be toward front.
17. With sealer, install new gasket onto transmission
case extension housing.
Installing Reverse Idler Gear and Reverse Gear
Shifter Shaft1. Inspect shafts carefully for burrs, and remove with
emery cloth. Burrs on shifter shaft will prevent easy
installation of shifter yoke. Lightly oil with transmis-
sion oil prior to installation. Place lock ball into
reverse idler gear shaft and push shaft through hole
in rear of case and on through reverse idler gear
which should have groove end toward front. See Fig-
ure
7B-46.Continue to drive reverse idler gear shaft forward
with plastic hammer until rear end of shaft is flush
with rear case face.
2. Position reverse speed shifter yoke in groove of
reverse idler gear and install reverse gear shifter shaft
from rear of case with notches up, pushing it through
reverse speed shifter yoke. See Figure
7B-47.3. Install spiral pin to secure yoke to shifter shaft and
drive plug into hole in rear of case.Figure 78.47 Third and Fourth Speed Shifter Shaft
Installed
Installing Mainshaft Assembly and Main Drive
Gear1. Slide mainshaft assembly into transmission case
from rear.
2. From the’front, slide mainshaft front ring and the
mainshaft needle bearing onto the mainshaft. See
Figure
7B-48.3. Install main drive gear through front of transmis-
sion case until main drive (standard part) snap ring
is flush with case.
Installing Third and Fourth Gear Shifter Shaft1. Position third and fourth speed yoke onto gear
shifter sleeve. See Figure
7B-47.2. Insert third and fourth gear shifter shaft through
hole in front of case with notches down, pushing it
through third and fourth speed yoke. Third and

MANUAL TRANSMISSION70.31COUNTER SHAFT GEAR
THRUST WASHER\Figure 76.48 Installing Spacer Ring and Needle
Bearing Onto Mainshaft
fourth speed yoke should be positioned with rounded
notch at shaft hole portion of yoke toward rear. See
Figure 78. 47.
3. Install spiral pin, allowing
i/16” to 5/64” of pin
to protrude.
Installing First and Second Gear Shifter Shaft
1. Inspect shifter shaft carefully for burrs, and
remove with emery cloth. Burrs on shifter shaft will
prevent easy installation of shifter yoke and cam.
Lightly oil with transmission oil prior to installation.
Insert first and second gear shifter shaft through hole
in rear of case with three notches down and toward
rear of transmission, pushing shaft tirst through
firstand second gear shifter yoke, which should be posi-
tioned on first and second gear sliding gear with
shoulder toward front of case. To position first and
second gear shifter yoke on first and second gear
sliding gear, push reverse idler gear forward, engag-
ing the idler gear with the first and second gear
sliding gear. This will make room for positioningfirst and second gear shifter yoke. See Figure
7B-49.2. Continue to drive first and second gear shifter
shaft through shifter shaft cam, which should be
positioned as shown in Figure
7B-50.3. Install spiral pins to secure shifter yoke and shifter
shaft cam to first and second gear shifter shaft.
Installing Selector Shaft
1. Inspect selector shaft carefully for burrs, andFigure
78.49 Countergear Thrust Washers Installed
Figure
78-50 Position of “L” Shaped Selector Dog
remove with emery cloth. Burrs on shaft will prevent
easy installation of intermediate levers. Lightly oil
with transmission oil prior to installation. Insert new
selector shaft oil seals in holes on both sides of trans-
mission case and insert selector shaft into case and
through third, fourth, and reverse intermediate lever.
Third, fourth, and reverse intermediate lever should
be positioned on selector shaft, as shown in Figure
7B-51.2. Continue to push selector shaft through first and
second intermediate lever and through other side of
case. First and second intermediate lever should be
positioned on selector shaft, as shown in Figure 7B-
52. Selector shaft is rotated counterclockwise (when
looking from lever end of selector shaft) from work-
ing position to have spiral pin holes in shaft vertical
and in line with pin holes in intermediate levers. To
rotate selector shaft in this manner, the reverse gear
shifter shaft and its reverse speed shifter yoke must
be pushed rearward so that the reverse idler gear is
against rear of case.

tiANUAL TRANSMISSION78.35
1’ Case, Transmission
2Gasket, Trans. Case to Clutch Housing
3 Cap, Ventilator
4 Gear, W/Bushings,
ReverSe Idler
5 Shaft, Reverse Idler Gear
6 Cluster Gear, Countershaft
7Washer, Trans. Counter Gear Thrust
8Roller. Trans. Counter Gear Bearing
9 Countershaft. Cluster Gear
10 Gear, Main Drive
11Spacer Ring, Trans. Counter Gear Bearing Roller
12 Bearing, Trans. Main Shaft Pilot
13 Ring, Trans. Main Drive Gear Ball Bearing Lock
14 Seal Ring, Main Drive Gear to Clutch
15 Shaft, Main
16 Ring, Trans. Main Shaft Snap Front
17 Needle Bearing, 1st Speed Gear on Main Shaft
18 Sliding Gear, 1st and 2nd Speed
19 Guide Unit, 1st and 2nd Speeding Sliding Gear
20 Gear. 3rd Speed
2
1Gear, 1 st Speed
22 Gear, 2nd Speed
23 Sleeve, Trans. Gear Shifter
24 Carrier, Trans. Gear Shifter Sleeve
25 Snap Ring, Trans. Gear Shifter Sleeve
26 Cone, Trans. 3rd and 4th Speed Syncronizer
27 Cone, Trans. 1st and 2nd Speed Syncronizer
28 Spring, Syncronizer (1st and 2nd Speed)
29 Spring, Syncronizer
30 Shoe, 1st and 2nd Speed Shifter
31 Shoe, 3rd and 4th Speed Shifter
32 Bearing, Trans. Main Shaft R.R.
33 Snap Ring, Trans. Main Shaft Ball Bearings
34 Washer, Main Shaft Between Inner Ball Bearing
and 1st Speed Gear
3j36
37
ii40
41
42
43
44
45
46
47
48
49
50
51
52
53
54Bearing, Trans. Main Shaft Needle
- Right
Gear, Speedometer Drive
Washer, Speedo Drive Gear
Ring, Speedo Drive Gear Snap
Retainer,
R.R. Bearing
Oil Seal, Trans. R.R.
Gasket, R.R. Bearing Retainer
Bushing. Trans. Main Shaft
- R.R.
Clip, Speedo Gear
Guide, Speedo Drive
Gear, Speedo Driven
Seal, Speedo
- Shaft Sleeve
Bracket, Speedo and Guide on Trans.
Seal Ring, Speedo Drive Guide
Cover, Trans. Case
Gasket, Trans. Case Cover
Shifter Shaft, 1st and 2nd Speed
Shifter Shaft, 3rd and 4th Speed
Shaft, Reverse Speed Shifter
Intermediate Lever, 1st and 2nd Speed
Shifter
55
Lever, Reverse Shifter Intermediate
56Lever, Intermediate 3rd. 4th and Reverse
57Seal, Shifter Shaft Oil in Trans.
58Cam. on Shifter Shaft
59Shifter Shaft, Intermediate Lever Reverse
60
Shaft, W/Lever and Bolt, in Trans.
61
Fork (Yoke), Reverse Speed Shifter
62Yoke, Trans. Shifter (1st and Reverse)
63Fork (Yoke), Trans. 2nd and 3rd Speed
64
Spring, Trans. Gearshift Interlock Thrust
65
Detent Spring, Reverse Speed Gearshift
66Interlock
Plug, Gearshift Interlock Detent

7C- 361973 OPEL SERVICE MANUAL
CONTENTS
Subject
DESCRIPTION AND OPERATION:
Description of the Opel Three-Speed Automatic,Transmission....................................................................
Principles of Operation....................................................
ComponentOperation
andLocation............................
Mechanical Operation......................................................
Hydraulic Control Units and Valves............................H,y&aulic Operation..........................................................
DIAGNOSIS:
Sequence for Trouble Diagnosis..................................
Checking
Procedures........................................................
ExternalOil
Leaks..............................................................
Trouble
DiagnosisChart..................................................
Hydraulic Pressure
Checks............................................
MAINTENANCE AND ADJUSTMENTS:
Detent Cable Adjustment..............................................
ServicingSelector
Lever..................................................
MAJOR REPAIR:
Transmission Removal and Installation
AllModels........................................................................
Removalof
OilPan............................................................
RemovalofValveBody....................................................
Removalof
ServoPiston................................................
Removalof
Selector
LeverandShaft........................
RemovalofModulatorAssembly..................................
RemovalofDetentValveAssembly............................
RemovalofExtensionHousing......................................
Removal of Speedometer Drive Gear, Governor
Body and Governor Hub..............................................
Removal of Converter Housing, Oil Pump, Reverse
and Second Clutch Assembly..................................
Removal of Third Clutch Assembly, Planetary
Carrier Assembly, Reaction Sun Gear and Drum
Assembly and Low Bank............................................
Disassembly, Inspection and Reassembly of
Converter Housing, Oil Pump and Reverse Clutch
Disassembly, Inspection and Reassembly of
SecondClutch
................................................................
Disassembly, Inspection and Reassembly of
ThirdClutch....................................................................
Disassembly, Inspection and Reassembly of
Planetary Carrier
............................................................Page No.7c- 377c- 387c- 447c- 487c- 487c- 64
7C- 81
7C- 81IC- 817c- 827c- 877c- 917c- 937c- 947c- 99.7c- 99
7c-1007c-loo
7&l 01
7c-102
7c-102
7c-103
7c-103
7c-104
7c-105
7c-111
7c-114
7c-118

AUTOMATIC TRANSMISSION7c- 37
Disassembly, Inspection and Reassembly of
ReactionSunGearandDrum....................................
Disassembly, Inspection and Reassembly of
Governor Body................................................................
Disassembly, Inspection and Reassembly of
GovernorHub..................................................................
Disassembly, Inspection and Reassembly of
ExtensionHousing........................................................
Disassembly, Inspection and Reassembly of
Servo Piston....................................................................
Disassembly, Inspection and Reassembly of
ValveBody........................................................................
Disassembly, Inspection and Reassembly of
Case....................................................................................
InspectingandTestingConverter................................
InstallationofSelectorLeverandShaft....................
InstallationofLowBand................................................
Installation of Reaction Sun Gear and Drum..........
Installation of Output Shaft and Planetary
Carrier................................................................................
Installation of Second and Third Clutch Assemblies
IntoCase..........................................................................
InstallationofReverseClutch......................................
DeterminingSelectiveWasherSize............................
Installation of Converter Housing, Oil Pump and
Clutch Assembly............................................................
Installation of Governor Assembly..............................
InstallationofExtensionHousing................................
InstallationofSpeedometerDrivenGear..................
Installation of Detent Valve, Modulator Valve
and Modulator Assembly............................................
Installation and Adjustment of Servo........................
InstallationofValveBody..............................................
InstallationofOilPanandGasket..............................
Torque Converter..............................................................
SPECIFICATIONS:
GeneralSpecifications......................................................
7c.
7c-
,l
‘118
197c-1207c-1207c-1207C-121
7C-124
7C-125
7C-125
7C-125
7C-127
7C-127
7C-127
7C-128
7C-129
7C-129
7C-129
7c-130
7c-131
7c-131
7c-131
7C-132
7c-133
7c-134
7c-134DESCRIPTION AND OPERATION
DESCRIPTIONThe Opel Three-Speed Automatic is a fully auto-matic unit utilizing a torque converter and a Ravig-neaux planetary gear set, with three multiple disc
clutches and a single band to provide three forward
speeds and reverse. See Figure 7C-71. Automatic
upshifts and downshifts are controlled by road speed,
engine vacuum and an accelerator pedal connection
to the transmission.

Figure 7C-1 Quadrant In Park Position -Opel 1900
and Manta7C- 381973 OPEL SERVICE MANUAL
R
- Reverse enables the vehicle to be operated in a
reverse direction.
N
- Neutral position enables the engine to be
started and operated without driving the vehicle.
D
- Drive range is used for all normal driving
conditions and maximum economy and has three
gear ratios. Downshifts are available for passing
by depressing the accelerator partially at lower
car speeds and through the “detent” at higher car
speeds.
S or 2
- Second range adds new performance for
hilly terrain. It has the same starting ratio as Drive
range, but prevents the transmission from shifting
above second gear to retain second gear for
acceleration or engine braking as desired. Second
range can be selected at any vehicle speed, but
should not be used above the speed shown m the
Owner’s Manual. This is to prevent over-speeding
the engine. The transmission will shift to second
gear immediately and remain in second until the
vehicle speed or the throttle position is changed
to obtajn first gear operation in the same manner
as in Drive range.
L or 1
- Lo range can be selected at any vehicle speed,
but should not be used above the speed shown in the
Owner’s Manual. The transmission will shift to low
(1st) gear immediately and remain in 1st gear regard-
less of vehicle speed or throttle position. This is par-
ticularly beneficial for maintaining maximum engine
braking.
PRINCIPLES OF OPERATION
Torque ConverterThe torque converter acts as a coupling to transmit
engine torque, through oil, to the transmission power
train. It also multiplies the torque from the engine
under certain conditions of input and output speed.
Figure
7C-2 Quadrant in Park Position - GT Models
The quadrant has six positions indicated in the fol-
lowing order: (Opel 1900 and Manta) P,R,N,D,S,
and L (Figure
7C-1); and (GT) P,R,N,D,2, and 1
(Figure 7C- 2).The torque converter used in the Opel three speed
automatic transmission consists of three basic ele-
ments: the pump (driving member), the turbine
(driven or output member) and the stator (reaction
member). See Figure
7C-3. The converter cover is
welded to the pump to seal all three members in an
oil tilled housing.
P
- Park position enables the transmission output
shaft to be locked
- thus preventing the vehicle
from roling either forward or backward. Because
the output shaft is mechanically locked by a
parking
paw1 anchored in the extension housing,
the park position should not be selected until the
vehicle has come to a stop. The engine may be
started in the Park position.Whenever the engine is running, the converter pump
turns at engine speed and acts as a centrifugal pump,
picking up oil at its center, adding energy, and dis-
charging the oil at its outer rim between the blades.
The shape of the converter pump shells and blades
cause the oil to leave the pump spinning in a clock-
wise direction toward the blades of the turbine. Asthere is no mechanical connection between converterpump and turbine, the oil is the only driving force
and strikes the blades of the turbine, transferring the