service OPEL 1900 1973 Service Manual

7C. 901973 OPEL SERVICE MANUALSHIFTBOOSTSUCTIONREVERSE ,UNEMO/DULATORSERVO RELEASE
LOW SERVO, APPLY
-REGULATOR
DRIVE
RNOR7076
Figure 7C-76 Case Bottom

7C- 92
1973 OPEL SERVICE MANUAL
Figure 7C-84Figure
7C-855. Unhook detent cable from detent valve. See Figure7c-87.
6. Pry detent cable pipe out of retainers.
7. Unscrew upper and lower adjuster nuts and
remove detent cable (on Manta models, loosen lock
nut and screw adjuster out of bulkhead).
Installation
1. Route cable and place in retainers,
2. Place cable in upper bracket and install upper and
lower adjuster nuts and retainer (on Manta models,
screw adjuster into bulkhead).
3. Hook detent cable to valve and install retainer.Figure
7C-86Figure
7C.87
AdjustmentBefore carrying out any adjustment to the detent
cable, it is essential that the throttle control linkage
is correctly adjusted so that full throttle opening is
obtained at the carburetor.
After the throttle control linkage has been set, the
adjustment for the detent cable may be checked as
FOllOWS:1. Position accelerator to full throttle (pedal is nol
fully depressed at full throttle) and loosen and
tighten upper and lower adjuster nuts of detent cable

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”,

7C- 961973 OPEL SERVICE MANUAL
Figure 7C-96
10. Detach rear engine support from transmission
crossmember. See Figure 7C-97.Figure 7C-98
Figure
7C-9711. Support transmission below oil pan with a suita-
ble jack.
12. Unscrew transmission crossmember from side
members. See Figure
7C-97.13. Lower transmission as far as possible,
14. Drain transmission oil.
15. Detach selector rod from ball pin of the outer
transmission selector lever on right transmission
side. See Figure
7C-98.16. Unscrew oil cooler pipes from transmission cow-
ter holding with a second wrench. Then plug oil
cooler pipes. See Figures 7C-99 and
7C-101.Figure 7C-99
17. Pull modulator line off diaphragm.
18. Unscrew detent cable retainer from transmission,
pull cable out of transmission, and unhook from de-
tent valve. See Figures 7C-102, 7C-103, and 7C-104.

7C- 981973 OPEL SERVICE MANUAL
Figure 7C-105Figure
7C-106Installation GT
1. Assemble transmission to suitable jack and raise
into position. Rotate converter to permit coupling
with flywheel in original relationship. Remove hold-
ing fixture.
2. Install tiller tube and converter housing to engine
bolts. Torque to 35
lb.ft.3. Install flywheel to converter bolts. Torque to 30
lb.ft.4. Install detent cable.
5. Connect oil cooler lines.6. Install lower bolt on starter. Torque to 40 lb.ft.
7. Connect modulator line.
8. Connect speedometer cable.
9. Connect shift linkage.
10. Install transmission support.
11. Install drive shaft. Torque U-bolts to 18 lb.ft.
12. Install flywheel cover pan.
13. Reconnect exhaust system and heat shield.
14. Install engine support brackets.
15. Lower car,
16. Install starter bolts, Torque to 40
lb.ft.17.
C:onnect battery.
18. Fill transmission with fluid, as described in
Specifications. Check selector lever and detent cable
adjustment.
DISASSEMBLY, INSPECTION AND REASSEMBLY
Transmission Installation Into Holding FixtureI. Remove transmission tiller tube.
2. With transmission on cradle of portable jack,
remove converter assembly by pulling straight out.
Converter contains a large amount of oil.
3. Install holding fixture, J-8763-01, on transmission.
4. Install holding fixture and transmission into hold-
ing base tool J-3289-20 with bottom pan up. See
Figure
7C-107. Do not overtighten.
Figure
7C-107

7C-1001973 OPEL SERVICE MANUALFigure 7C-1 12
Figure
7C-1 136. Remove the two check balls located in the oil
passages in the transmission case. See Figure
7C-114.Location of these check balls must be noted so that
they are installed correctly.
Removal of Servo PistonThis operation can be performed with transmission
in vehicle
1. Compress servo piston using servo piston com-
pressor tool J-23075.
Figure7C-1 14
2.Using pliers,
remove servo pistonsnap ring.SeeFigure
X-1 15.
Figure
7C-1 153. Loosen servo piston compressor tool J-23075
slowly as servo is under high spring tension. Remove
tool and servo piston assembly. See Figure
7C-116.
Removal of Selector Lever and ShaftNote at this point that the selector lever (on GT
models only) is on the opposite side from all other
models, and that the selector shaft passes through
the case. See Figures 7C-117 and 7C-118. Note also

AUTOMATIC TRANSMISSION 7C-101
Figure 7C-1 16
-117Figure
7C-118 GT Models
Figure 7C-1 17 GT Modelsthat one case services both models and is machined
to accept selector lever on either side with the unused
hole being plugged.
1. Remove retaining ring From parking actuator rod
to selector inner lever. See Figure 7C-119.
2. Remove selector inner lever locking nut from se-
lector lever shaft.
3. Remove selector inner lever from selector lever
shaft.4. Remove selector lever shaft spring pin by pulling
upwards with small pliers.Figure
7C-1195. Remove selector lever shaft. See Figure 7C-120.
6. Remove selector lever shaft oil seal and discard.
Removal of Modulator Assembly
This operation can be performed with transmission
in vehicle using tool J-23
100.1. Remove vacuum modulator From transmission
case. See Figure
7C-94. Care should be taken not to
lose the modulator plunger.

7C-1021973 OPEL SERVICE MANUAL
Figure 7C-120Figure 7C-122
Figure 7C-12 1
2. Remove modulator valve and sleeve from trans-
mission case.
Removal of Detent Valve Assembly
This operation can be performed with transmission
in vehicle
1. Remove spring pin by pulling upward with pliers.
2. Lightly tap detent valve assembly from front of
case and remove detent valve, sleeve, spring, and
spring seat from rear of easel See Figure 7C-122,Removal of Extension Housing
This operation can be performed with transmission
in vehicle
1. Remove bolt holding speedometer driven gear
housing retainer and carefully remove retainer and
pull speedometer driven gear assembly from exten-
sion housing. See Figure
7C-123.Figure
7C- 123
2. Remove the seven attaching bolts from extension
housing to case.

7C-1041973 OPEL SERVICE MANUAL
bolts which are the outer bolts in the housing. See
Figure 7C-129.
Figure 7C-129
3. Remove converter housing with oil pump, reverseand second clutch assemblies. Do not lose selective
thrust washer. See Figure
7C-130. Second clutch as-
sembly may remain in case. If so, remove with re-
verse clutch plates.
Figure 7C-130
4. Remove reverse clutch plates from transmission
case, See Figure
7C-131.
T%RSE~L~~T~H PLATES
7c-131
Figure
7C-13 I
Removal of Third Clutch Assembly. Planetary
Carrier Assembly, Reaction Sun Gear and Drum
Assembly and Low Band1. Remove third clutch assembly. See Figure 7C-
132.
Figure 7C-132
2. Remove planetary carrier and output shaft by slid-
ing out through front of case. See Figure
7C-133.Care should be taken not to lose the needle thrust
bearing and race in the planetary carrier assembly.
3. Remove reaction sun gear and drum with needle

7C-1061973 OPEL SERVICE MANUAL
Figure 7C-138
!LREVERSEZH
)N
OIL PUMP
t7c-1382. Remove selective washer from oil pump shaft. See
Figure
7C-138.3. Remove the oil pump outer oil seal and discard.
See Figure
7C-139.Figure 7’2.139
4. Remove the five bolts holding the converter hous-
ing to the oil pump.
5. Remove the converter housing. See Figure 7C-
140.6. Remove oil pump wear plate “A”. See Figure 7C-
140.Figure
7C-1407. Inspect front face of converter housing for oil leak.
See Figure
7C-141. If problem is diagnosed as a front
seal leak (presence of red oil coming from bottom of
converter housing), remove front oil seal.
7c141Figure
7C-1418. Inspect converter housing bushing. If worn,
remove bushing using tool J-21465-17 with drive
handle J-8092 from converter side of housing.
9. Clean converter housing thoroughly. Install con-
verter housing bushing flush with front face of hous-
ing using tool J-21465-17 with driver handle J- 8092.
See Figure
7C-142.