lock OPEL GT-R 1973 Service Manual

CLUTCHlA- 9
1.2.3.4.
8.
-9.
-11.BRACKET
1.“E” RING12.CABLE
2.WASHER13.RELEASE LEVER
3.RUBBER GROMMET
14.BALL STUD4.CLUTCH OPERATINGDAMPER
15.CLUTCH HOUSING
5.GROMMET16.BALL STUD LOCK NUT
6.WASHER17.RUBBER BELLOWS7.
“E” RING18.CABLE SUPPORT BRACKET
8. ADJUSTMENT SWITCH19. NUT, CABLE SUPPORT BRACKET
9.CLUTCH PEDAL20.DISTANCE BETWEEN RELEASE
10. RETURN SPRING
LEVER AND CLUTCH HOUSINGJA-7
Figure JA-7 Clutch Pedal Adjustment
- Opel 1900 and Manta

7A- 101973 OPEL SERVICE MANUAL
Arrangement Of Clutch
1 Clutch release lever14 Clutch ossy. bolt, lockwasher
2 Slot in lever for control cable boll15 Hollow space under felt ring filled
endwith molybdenum disulfide paste
3Assembly marks
4Clutch assembly
5Flywheel
6 Flywheel ring gear
7Thrust pin
8Retaining spring
9Crankshaft
10 Clutch gear pilot bushing
11Oil seal
12Flywheel bolt
13Clutch housing
16 Felt ring
17 Clutch release bearing
18 Clutch gear ball beorirq
19 Clutch gear
20 Snap ring
21 Paper gasket
22 Clutch gear oil seal
23 Clutch release bearing sleeve
24 Clutch disc, long end of hub facing
forward.
?A-8Figure
7A-8 Arrangement of Clutch

7B- 121973 OPEL SERVICE MANUAL
MANUAL TRANSMISSION
CONTENTS
Subject
DESCRIPTION AND OPERATION:
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Power
Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DIAGNOSIS: (Not Applicable)
MAINTENANCE AND ADJUSTMENTS:
Adjusting
ReverseGearshiftBlocker. . . . . . . . . . . . . . . . . . . . . . . . . .Shift Lever Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ServicingGearshift
Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .MAJOR REPAIR:
Transmission
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installation
ofTransmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing and Installing
Speed0 Driven Gear
(Transmission
Removed). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ReplacingBushinginSelectorLever. . . . . . . . . . . . . . . . . . . . . . . . . .Transmission
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Transmission
Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPECIFICATIONS:
Specifications ..,....._....,......,.....,......,.,.....,,.,..,......,.,....,........
Page No.
78-12
7B-13
78-1978-l
9
7B-19
78-22
78-22
78-23
78-23
78-23
78-28
78-33

7B- 141973 OPEL SERVICE MANUAL
POWER FLOW - 1st SPEED
MAIN DRIVE GEAR (INPUT)
COUNTERSHAFT GEAR UNIT 1st SPEED GEAR
1 st SPEED GEAR
1st AND 2nd GEAR SLIDING GEAR1st AND 2nd SPEED SLIDING GEAR GUIDE UNITCOUNTERSHAFT GEAR
UI‘!IT DRIVE GEAR1st SPEED GEAR1st AND 2nd GEAR SLIDING GEAR
,st AND 2nd SPEED SLIDING GEAR GUIDE UN1MAINSHAFT (OUTPUT)
70-2Figure 78.2
First SpeedAfter synchronizing the speeds of the mainshaft and
the 1st speed gear, the 1st and 2nd gear sliding gear
shifts to the rear of the transmission and locks the 1st
speed gear to the mainshaft through the 1st and 2nd
speed sliding gear guide unit. This 1st and 2nd speed
sliding gear guide unit is internally splined to the 1st
and 2nd gear sliding gear and is
exl~ernally splined to
the mainshaft. Both the 3rd speed gear and the 2nd
speed gear are idling. The reverse idler gear is not
engaged with any gear and, therefore, it is idle.
With a 1st speed gear ratio of
3.428:1, the main drive
gear (input) must turn 3.428 revolutions for every
one revolution of the main shaft (output).
IT

MANUAL TRANSMISSION76.15POWER FLOW. 2nd SPEED
MAIN DRIVE GEAR (INPUT)
COUNTERSHAFT GEAR UNIT 2nd SPEED GEAR
2nd SPEED GEAR
1st AND 2nd GEAR SLIDING GEAR
1st AND 2nd SPEED SLIDING GEAR GUIDE UNITCOUNTERSHAFT GEAR UNIT DRIVE GEAR
2nd SPEED GEAR
1st AND 2nd GEAR SLIDING GEAR
Ist AND 2nd SPEED SLIDING GEAR GUIDE UIMAINSHAFT (OUTPUT)
76Figure 78.3
Second SpeedAfter synchronizing the speeds of the mainshaft and
the 2nd speed gear, the 1st and 2nd gear sliding gear
shifts toward the front of the transmission and locks
the 2nd speed gear to the mainshaft through the 1st
and 2nd speed sliding gear guide unit. This 1st and
2nd speed sliding gear guide unit is internally splined
to the 1st and 2nd gear sliding gear and is externally
splined to the mainshaft. Both the 3rd speed gear and
the 1st speed gear are idling. The reverse idler gear
is not engaged with any gear and, therefore, it is
idle.
With a 2nd speed gear ratio of
2.156:1, the main
drive gear (input) must turn 2.156 revolutions for
every one revolution of the mainshaft (output).
VIT
i-3

78. 161973 OPEL SERVICE MANUAL
POWER FLOW
- 3rd SPEED
MAIN DRIVE GEAR (INPUT)
COUNTERSHAFT GEAR UNIT 3rd SPEED GEAR
3rd SPEED GEAR
GEAR SHIFTER SLEEVE
GEAR SHIFTER SLEEVE CARRIERCOUNTERSHAFT GEAR UNIT GEAR DRIVE
3rd SPEED GEAR
GEAR SHIFTER SLEEVE
GEAR SHIFTER SLEEVE CARRIER
MAIN SHAFT (OUTPUT)
78-4
Figure 78.4
Third Speed
After synchronizing the speeds of the mainshaft and
the 3rd speed gear, the gear shifter sleeve shifts to the
rear of the transmission and locks the 3rd speed gear
to the mainshaft through the gear shifter sleeve car-
rier. This gear shifter sleeve carrier is internally
splined to the gear shifter sleeve and is externally
splined to the mainshaft. Both the 1st speed gear and
the 2nd speed gear are idling. The reverse idler gear
is
not engaged with any gear and, therefore, it is
idle.
With a 3rd speed gear ratio of
1.366:1, the main drive
gear (input) must turn 1.366 revolutions for every
one revolution of the mainshaft (output).

MANUAL TRANSMISSION78.17POWER FLOW
- 4th SPEED
MAIN DRIVE GEAR (INPUT)
GEAR SHIFTER SLEEVE
GEAR SHIFTER SLEEVE CARRIERGEAR SHIFTER SLEEVE
GEAR SHIFTER SLEEVE CARRIER
MAIN SHAFT (OUTPUT)7E5
Figure 78.5
Fourth SpeedAfter synchronizing speeds of the main drive gear
and mainshaft, the gear shifter sleeve shifts forward
and locks the main drive gear to the mainshaft
through the gear shifter sleeve carrier. This carrier is
internally splined to the gear shifter sleeve and is
externally splined to the mainshaft. The 3rd speed
gear, 2nd speed gear, and the 1st speed gear are all
idling. The
reverse idler gear is not engaged with
any gear and, therefore, it is idle.
With a 4th speed gear ratio of 1.000: 1, the main drive
gear (input) must turn 1.000 revolutions for every
one revolution of the mainshaft (output).

MANUAL TRANSMISSION76.19
DIAGNOSIS
MANUAL TRANSMISSION DIAGNOSIS
ConditionPossible CauseNoisy in Forward Speeds1) Low lubricant level.
2) Incorrect lubricant.
3) Transmission misaligned or loose.
4) Front main bearing worn or damaged.
5) Mainshaft bearing worn or damaged.
6) Countergear or bearings worn or damaged,
7) Main drive gear worn or damaged.
8) Synchronizers worn or damaged.
Noisy in “Reverse”1) Reverse sliding gear or shaft, worn or damaged
Hard Shifting1) Clutch improperly adjusted.
2) Shift shafts, or forks worn.
3) Incorrect lubricant.
4) Synchronizers worn or broken.
Jumping Out of Gear1) Partial engagement of gear.
2) Transmission misaligned or loose.
3) Worn pilot bearing.
4) End play in main drive gear (bearing retainer
loose or broken, loose or worn bearings on
main drive gear and mainshaft).
5) Worn clutch teeth on main drive gear and/or
worn clutch teeth on synchronizer sleeve.
6) Worn or broken blocking rings.
7) Bent mainshaft.
Sticking in Gear1) Clutch not releasing fully.
2) Low lubricant level.
3) Incorrect lubrication.
4) Defective (tight) main drive gear pilot
bearing.
5) Frozen blocking ring on main drive gear cone.
6) Burred or battered teeth on synchronizer
sleeve and/or main drive gear.
MAINTENANCE AND ADJUSTMENTS
ADJUSTING REVERSE GEARSHIFT BLOCKER1. Engage second speed.
2. Adjust selector ring (a) so that ball on lower end
of shift finger has an equal clearance on both sides
when seated into the transmission case extension bolt
hole. See Figure
7B-7.3. Back off selector ring an additional
l/4 of a turn
and tighten lock nut (B). See Figure
7B-7.SERVICING GEARSHIFT LEVER
Removal1. Unscrew console from floor panel, on small con-
sole remove three (3) attaching screws, on large con-
sole remove four (4) attaching screws. The fourth
screw is accessible after removal of the ash tray. See
Figure
7B-8.2. Remove rubber bellows from cover plate and from
below unbutton protective cap arranged around in-
termediate shift lever.

76.201973 OPEL SERVICE MANUAL
GEARSHIF
INTERMEDIATE SHAFT,
.SHIFT
FINGER1SELECTOR LEVER
JT “B’
78-7Figure’7B.7 Reverse Gearshift Blocker Adjustment
Figure
78-B3. Unhook tension spring of gearshift lever and, after
removal of retaining washer, push pivot pin out of
intermediate shift lever. See Figure
7B-10.1. Prior to installation, grease support and spherical
end of shift finger with protective grease.
2. Replace lever, pivot pin, retaining washer, and
tension spring. Reposition protective cap and bel-
lows and button cap from below. Replace console.
3. In
Figuie 7B-11, distance A - 8.07”.Figure 7B-10
7&l 1Figure 78.1 1
4. After installation, check as to whether pull ring
can be lifted up approximately
.04 to .08”, whereby
the stop sleeve must still rest against intermediate
shift lever. Otherwise, loosen threaded pin forBowden control wire attachment. See Figure 7B- 12.
Adjust distance B
- free travel - by lifting up pull
ring, and retighten threaded pin. See Figure 7B- 13.
REPLACING BOWDEN CONTROL WIRE IN
GEARSHIFT LEVER
1. Remove gearshift lever.

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.