lock OPEL GT-R 1973 Service Manual

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.

MANUAL TRANSMISSION70.235. Attach clutch cable.
6. Perform clutch lash adjustment. See Clutch, Sec-
tions A and B for adjustment procedure.
7. After overhaul of transmission, refill with
2- l/2pints of SAE 80 or SO-90 multi-purpose gear Iubri-
cant.
REMOVING AND INSTALLING SPEED0 DRIVEN
GEAR
(WITH TRANSMISSION REMOVED)
Removing Speedo Driven Gear Assembly1. Use wrench to unscrew speed0 angular drive hold-
ing nut and remove speedo angular drive.
2. With Special Tool J-22926 and Slide Hammer
J-7004- 1, remove speedo driven gear lock pin which
retains speed0 driven gear assembly in transmission
case extension housing.
3. Using Special Tool J-22929 and Slide Hammer
J-7004- 1, remove speed0 driven gear assembly. Tool
J-2292? screws onto the speedo driven gear guide
making it possible to remove the guide and assembly
without damage to the transmission case extension
housing.
Installation of Speedo Driven Gear Assembly1. Using Special Tool J-22929 install speedo driven
gear assembly into transmission case extension hous-
ing. It may be necessary to tap lightly on tool
J-22929 when installing assembly. Be sure speedo
driven gear lock pin hole on guide lines up with hole
in transmission case extension housing. Also, rotate
mainshaft at output end when inserting speed0
driven gear assembly to insure that driven gear
meshes properly with speed0 drive gear on main-
shaft.2. Install speed0 driven gear lock pin into transmis-
sion case extension housing by tapping pin lightly.
3. Install speed0 angular drive by tightening speedo
angular drive to holding nut.
REPLACING BUSHING IN SELECTOR LEVER
(TRANSMISSION AND GEARSHIFT LINKAGE
REMOVED)
Removal1. Remove snap ring from bushing. See Figure 7B-
17.2. Using a suitable brass drift drive out bushing from
snap ring side. See Figure
7B-19.SNAP RING
Figure 78.17 Snap Ring on Selector Intermediate
Lever Bushing
Figure 78.19 Removing Bushing From SelectorIntermediate Lever
Installation1. Using a suitable tool drive in bushing up to stop.
Install bushing in opposite direction of removal with
the cutout in the bushing facing upwards. See Figure7B-
19.2. Install snap ring onto bushing.
TRANSMISSION DISASSEMBLYMaintain the respective positions of all mating parts
during overhaul.

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

78.261973 OPEL SERVICE MANUAL
4. Remove both first and second speed shifter yoke
and shifter shaft cam.
Removing Main Drive Gear and Mainshaft
Assembly
1. From front of transmission, pull main drive gear
and needle bearing out of transmission. (May be
necessary to rock main drive gear.)
2. From rear of transmission, pull mainshaft assem-
bly and transmission case extension housing out of
transmission. Gear shifter sleeve will be pulled off
gear shifter sleeve carrier by the third and fourth
speed shifter yoke. Remove sleeve from yoke and
keep sleeve with mainshaft assembly. (Make sure
third and fourth speed shoes are not lost.)
Removing Third and Fourth Gear Shifter Shaft.
1. With main shaft assembly out of transmission
case, drive third and fourth gear shifter shaft out
through hole in front of case with brass drift from
rear of transmission through mainshaft assembly
hole in case.
2. Remove third and fourth speed yoke.
Removing Reverse Gear Shifter Shaft and Reverse
Idler Gear
1. Using a brass drift and from the front of the trans-
mission, drive out reverse gear shifter shaft and plug.
See Figure
7B-28. The reverse speed shifter yoke will
remain in transmission case.
Figure 78.28 Removing Reverse Shifter Shaft
2. With Special Tool J-22923 push reverse idler gear
shaft from front toward the rear. Ensure that lock
ball is not lost. See Figure
7B-29.Figure 78.29 Removing Reverse Idler Gear Shaft
3. Take shaft, reverse idler gear and reverse speed
shifter yoke out of transmission case.
Disassembling Mainshaft Assembly
1. Remove mainshaft bearing snap ring from trans-
mission case extension housing groove and remove
mainshaft assembly from housing. See Figure
7B-30.Figure 78-30 Removing Snap Ring From Rear Bearing
Retainer2. Remove loose parts such as mainshaft needle bear-
ing, mainshaft front ring, synchronizer cover, gear
shifter sleeve, shoes, and front synchronizer spring.
The gear shifter sleeve carrier and the first and sec-
ond speed sliding gear guide unit and their respective
gear shifter sleeve and first and second gear sliding
gear are selected assemblies and should be kept
together as originally assembled. See Figure 7B- 31.

MANUAL TRANSMISSION78-27
SYNCHRONIZER
SPAZER RINGf&31Figure 78.31
3. Remow snap ring from in front of clutch hub. See
Figure
7B-32.
SPEED
DRIVEFigure 78.33 Removing Snap Ring Behind
Speedometer Drive Gear
CLUTCH HUBFigure
7%.32 Removing Snap Ring In Front of ClutchHub4. Using Tru-arc pliers, remove snap ring behind
speedometer drive gear. See Figure
7B-33. Removespeedo drive gear spring washer and speed0 drive
worm gear.
5. Remove drive gear lock ball from mainshaft. See
Figure
7B-34.6. Press mainshaft inner bearing from mainshaft us-
ing Special Tool J-21684, Press Plate, as shown in
Figure 7B-35 and then, by hand, remove all loose
parts such as mainshaft washer, transmission case
extension housing snap ring, first speed gear, first
speed needle bearing, synchonrizer cover, first and
second gear sliding gear, shoes, and rear synchro-
nizer spring, See Figure
7B.370DRIVE GEAR
LOCK BALL
Figure 78.34
Speedo Drive Gear I.ock Ball on Mainshaft
l-21 684
BALL
BEARING
/
Figure 78.36 Removing Rest Bearing Frotii Mainshaft

MANUAL TRANSMISSION78.29
5. Using external snap ring pliers, secure gear shifter
sleeve carrier on mainshaft with snap ring. See Fig-
ure
7B-40.6. From rear of mainshaft, slide second speed gear
onto mainshaft. Gear must turn freely on mainshaft.
See Figure
7B-41.
2ND SPEED
GEAR CONE\
3RD SPEED
GEAR
MAIN
L; SYNCHRONIZER
VER2ND SPEED
GEAR
7B.41Figure
7B-41 Second Speed Gear and Synchronizer
Ring Installed
7. Place second speed synchronizer cover onto sec-
ond speed gear cone. See Figure
7B-41.
8. Install both synchronizer springs into first and
second speed sliding gear guide unit so that hooks of
both springs rest in the same guide unit shoe slot and
the other spring ends are positioned opposite to each
other. See Figure 78-42.
9. Press first and second speed sliding gear guide unit
onto mainshaft so that the original tooth contact is
obtained.
10. Using Tool J-22913, press first speed gear needle
bearing inner sleeve onto mainshaft.
11. Using Tool J-22913, install tirst and second speed
shoes (long style) and install first and second gear
sliding gear (forked groove to rear) onto first and
second speed sliding gear guide unit.
12. Slide first speed gear needle bearing, synchro-
nizer cover, first speed gear, mainshaft washer
(chamfer toward rear), and mainshaft bearing snap
ring onto mainshaft.
13. Press on mainshaft inner bearing using Tool
J-22913. See Figure
7B-43.GUIDE UNIT
SYNCHRONWER SPRING
Figure 78.42 Both Clutch Key Springs Installed
RI
d-J-22913 MAINSHAFT
ASSEMBLY TOOL
---- .
~.
7B.uFigure 78.43 Pressing on Rear Bearing Using Tool
J-22913
14. Insert lock ball in place in mainshaft and place
speedo drive worm gear and speed0 drive gear spring
washer on mainshaft. Secure with speedo drive gear
snap ring.
15. Place mainshaft assembly into transmission case
extension housing up to its stop. Secure with main-
shaft bearing snap ring. See Figure 7%44.

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.

Figure 78-5 1 Position of Third, Fourth, and Reverse
Intermediate Lever on Selector Shaft
1ST. 2ND IlrFigure 78.52 Position of First and Second
Intermediate Lever on Selector Shaft
3. Install spiral pins to secure both intermediate lev-
ers to the selector shaft. Spiral pins should not be
flush with lever surface, but rather should extend up
between
l/16 and 5/64 inches.
Installing Reverse Speed Shifter Intermediate
Lever and Interlock Balls, Springs, and Plugs
1. Engage reverse speed shifter intermediate lever
with third, fourth, and reverse intermediate lever and
also in slot in reverse gear shifter shaft, and install
79-321973 OPEL SERVICE MANUAL
bedding bolt through reverse speed shifter intermedi-
ate lever and into case. Reverse speed shifter inter-
mediate lever end play on bolt should be between
,004 and .012 inches.
2. Insert both interlock balls and then springs, and
drive both interlock plugs into case holes until they
bottom in interlock plug hole seats. Grooves in plugs
will be showing.
Installing Countershaft Gear Unit
1. Coat thrust washers with ball and roller bearing
grease and stick to transmission case. Lugs of thrust
washers must fit into transmission case slots. See
Figure
7B-49.2. Turn transmission case extension housing until
gear unit countershaft bore is completely exposed.
3. Place lock ball into shaft and from the rear of the
transmission insert shaft so that thrust washer is held
in position. Hold opposite thrust washer in position
by using a short drift.
4. Insert countershaft gear unit into transmission
case. Be sure all needle bearings and both needle
bearing washers are in place.
5. Insert gear unit countershaft into gear unit and
drive shaft into transmission case while driving out
Special Tool J-2291 1. Pay attention to lock ball. See
Figure
7B-53.Figure 78-53 Installing Countergear Shaft
Installing Transmission Case Extension Housing
1. Align transmission case extension housing and
gasket and torque (3) bolts with spring washers to 21
lb. ft.