OPEL 1900 1973 Service Manual

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

AUTOMATIC TRANSMISSION 7C- 91
MAINTENANCE AND ADJUSTMENTS
DETENT CABLE REPLACEMENT AND
ADJUSTMENT
The reliability of the detent bowden control cable is
greatly dependent upon the proper adjustment of the
wire whenever installation is being made. It is impor-
tant to remember that the free end of the wire is not
kinked, as individual strands will break due to the
continuous bending during operation. To avoid this
situation, it is important that the bowden control
cable be properly installed. Although replacement
and adjustment procedures on various models are
identical, the location of the upper, or throttle, end
of the detent cable may vary. For proper model iden-
tification, see Figures
7C-61, 7C-62, 7C-63, and 7C-
64.Figure JC-79 Opel 1900 and Manta
Figure
7~80 Opel 1900 and MantaFigure JC-81 GT Models
Figure JC-93 GT Models
Removal
I. Detach retainer at detent cable to accelerator link-
age.2. Loosen rear transmission crossmember from body
and remove right side bolt. See Figure
7C-84, Callout
” A ”3. Insert block of wood between floor pan and right
rear corner of transmission to expose detent cable
bracket at transmission. See Figure
7C-85.4. Unscrew detent cable connecting retainer from
transmission and pull cable out of transmission. See
Figure
7C-86.

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

AUTOMATIC TRANSMISSION 7C- 93
(on Manta models, turn adjuster) until ball end of
cable rests firmly against lever.
2. At this point, measure length of exposed detent
inner cable. Depress accelerator pedal fu/fy, and
again measure inner cable. If correctly adjusted, de-
tent cable should move approximately 3/S inch.
Servicing Selector Lever1. Unscrew console from floor panel, on small con-
sole remove three (3) attaching screws and
on large
console remove four (4) screws. The fourth screw is
accessible after removal of ash tray. See Figure 7C-
88.Figure
7C-88Figure
7C-892. Unplug cigar lighter and lamps from console and
remO”e co”sole.
3. From below vehicle, remove selector rod from
intermediate selector lever.
4. Remove neutral start switch (A) and remove sup-
port housing attaching bolts. See Figure
7C-89.5. Remove support housing and, from the underside
of support housing, remove three (3) support attach-
ing bolts. See Figure
7C-90.Figure
7C-906. Remove intermediate selector lever (B) from shaft
and remove assembly from support housing. See Fig-
ure 7C-92.7GB2
Figure
7C.92

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- 95
12. Place suitable jack under transmission and
remove transmission support bolts.
13. Lower transmission enough to remove detent
cable and modulator vacuum line.
14. Remove speedometer cable.
15. Remove selector lever.
16. Mark flywheel and converter for reassembly in
same position, and remove converter to flywheel
bolts. See Figure 7C-106.17. Remove converter housing to engine bolts and
tiller tube.
18. Pry transmission loose from engine.
19. Keep rear of transmission lower than front to
prevent converter from falling and install converter
holding fixture J-21366. Lower transmission and
move to bench.
Installation. Opel 1900 and Manta1. Assemble transmission to suitable jack and raise
transmission into position. Rotate converter to per-
mit coupling of fly wheel and converter with original
relationship. Remove J-21366.
2. Install tiller tube and converter housing to engine
block bolts. Torque to 35 lb. ft. DO NOT over
torque.
3. Install flywheel to converter bolts. Torque to 30 lb.
ft.4. Install detent cable to transmission.
5. Connect oil cooler lines.
6. Install lower bolt on starter. Torque to 40 lb. ft.
7. Connect shift linkage to transmission.
8. Connect modulator line.
9. Connect speedometer cable.
10. Install transmission support.
11. Install drive shaft. Torque U-Bolts to 18 lb. ft.
12. Install flywheel cover pan. Torque to 15 lb. ft.
13. Install engine support brackets.
14. Reconnect exhaust system.15. Attach stabilizer supports and tighten stabilizer
bolts in lower control arms.
16. Lower car.
17. Install starter bolts. Torque to 40 lb. ft.
18. Reconnect battery.
19. Fill transmission with fluid as described in
Specifications. Check selector lever and detent cable
adjustment.
Removal GT1. Disconnect battery.
2. Remove dipstick.
3. Pull throttle control rod off ball pin.
4. Remove screws from fan shroud.
5. Raise car and provide support for front and rear.
6. Remove heat protection shield from right side to
make room for exhaust pipe removal.
Figure 7C-957. Detach exhaust pipe from manifold flange.
8. Unhook damper rings on front muffler and tail
pipe from brackets on body floor panel. Place ex-
haust pipe assembly onto rear axle. See Figure 7C-
96.9. Remove propeller shaft. Make sure that spring in
front universal joint does not get lost.

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.

AUTOMATIC TRANSMISSION JC- 97
Figure 7C-101Figure 7C-103
Figure 7C-102
19. Pry detent cable and oil cooler pipes out of retain-
ers on transmission oil pan.
20. Unscrew speedometer cable and pull it out of
speedometer driven gear housing.
21. On both engine sides unscrew engine support
brackets from torque converter housing. Slacken’
front attaching bolt only. See Figure
7C-105.22. Remove torque converter housing cover plate.Figure 7C-104
23. Mark flex plate and converter for reassembly in
same position.
24. Unscrew the three torque converter to
flex plate
attaching bolts. See Figure
7C-106.25. Pry transmission loose from engine.
26. Move transmission rearward to provide clear-
ance between converter and flex plate to install con-
verter holding tool J-21366. Lower transmission and
move to bench.

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

AUTOMATIC TRANSMISSION 7C- 99Converter Housing Oil SealWith transmission on portable jack and converter
removed, converter housing oil seal may be removed
without disassembling transmission using tool
J-23129, and slide hammer J-7004.
2. Using tool J-23129 remove oil seal with slide ham-
mer.3. Install new oil seal using installer J-21359.
Removal of Oil PanThis operation can be performed with transmission
in vehicle.
1. Remove the twelve oil pan attaching bolts.
2. Remove oil pan and gasket. See Figure
7C-108.Figure
7C-I 10Figure
7C-108
REMOVAL OF VALVE BODY
8 Removal of Valve BodyThis operation can be performed with transmission
in vehicle
1. Remove the manual detent roller and spring, re-
tained by two bolts. See Figure
7C-110.2. Remove the three attaching bolts holding the
strainer assembly to the valve body and remove. Dis-
card gasket.
3. Remove the eight bolts from transfer plate rein-
forcement and remove reinforcement. See Figure 7C-
111.Figure
7C-1 11
4. Remove the four servo cover attaching bolts and
remove servo cover and gasket. See Figure
7C-112.5. Remove remaining eight bolts attaching valve
body to case. Carefully remove valve body with gas-
ket and transfer plate. See Figure
7C-113.Care must be taken so that manual valve and manual
valve link “A” are not damaged or lost during re-
moval of valve body from the case.