OPEL GT-R 1973 Service Manual

49- 201973 OPEL SERVICE MANUAL
IN.LB. TORQUE
Figure 48.30 Checking Side Bearing Preload
4. With the use of a feeler gauge, check clearance
between differential side gears and case. See Figure
4B-31. Clearance should be ,003” to X106”. If clear-
ance is not within these limits, remove side gears and
install shims of correct thickness to obtain desired
clearance, reassemble and install pinion shaft lock
pin.
Figure 48.31 Checking Side Gear to Case Clearance
5. Install ring gear on case, making certain their
mating surfaces are free of burrs or foreign material.
Tighten bolts to 47
lb.ft.
6. Check lateral runout of installed ring gear. Max- imum permissible

runout is X03”. If runout is
greater than specified, make certain that dirt or burrs
are not holding the ring gear in a cocked position on
the case and that the bolts are evenly torqued.
7.
Imtall side bearings using Installer J-22919 and
Drive Handle J-8092. Support opposite side of case
on Pilot J-2241-1 1 to prevent bearing damage. See
Figure
4B-32.
DRIVER
HANDLE
J-8092
4B.27
Figure 48-32 Installing Differential Side Bearings
Figure
48.33 Installing Differential Case Assembly

REAR AXLE48.21FEELER
DIFFERENTIAL
DIAL INDICATOR
SIDE BEARINGS
Figure 48.34 Removing Differential Case and End
Play8. Determine differential side bearing preload and
backlash as follows:d. Adjust feeler gauge thickness from side to side
until ring gear backlash is
004” to ,008” (.005” is
desired).a. Position differential case assembly less side bear-
ing shims into the side bearing bores of the carrier.
See Figure
4B-33.b. Using two (2) sets of feeler gauges, insert feeler
stock of sufficient thickness between each bearing
outer race and the carrier to remove all end play.
Make certain the feeler stock is pushed to the bottomof the bearing bores. See Figure
4B-34.
e. With zero end play and correct backlash estab-
lished, remove feeler gauge packs, determine thick-
ness of shims required and add
.002” to each shim
pack to provide side bearing preload.
f. Remove case assembly and both side bearings us-
ing J-22588 with Adapter Leg J-22939 and Pilot
J-
2241-11.c. Mount Dial INDICATOR J-8001 on carrier sog. Install shim packs with respective side bearing
indicator stem is at right angles to a tooth on the ring
using Installer J-22919, Driver Handle J-8092 and
gear. See Figure
4B-34.Pilot J-2241-1 1.

48. 221973 OPEL SERVICE MANUAL
9. Position
case assembly and outer races in the car-
rier. Use a soft-faced hammer to drive the case into
the carrier until the side bearing outer races bottom
in their bores.
10. Install side bearing caps in their original location
and torque the bolts to 33
lb.ft.IN. LB. TORQUL
11. Rotate case assembly several times to seat the
bearings. Check backlash and preload using a torque
wrench on a ring gear attaching bolt. See Figure 4B-
35. Torque required to turn case should be 20 to 30
Ib.in. for new bearings or 10 to 20 lb.in., for used
bearings. If torque is not correct, it will be necessary
to r&him the side bearings.
12. Insta!l torque tube assembly.
13. Install axle shafts.Figure 48.35 Checking Side Bearing
Preload
SPECIFICATIONS
DIFFERENTIAL SPECIFICATIONS
General SpecificationsRear Axle Type
.,,...,,,...,,_...._..,,...,,,...,,,....,,.,...,,.,,...,,..,,,........................ Semi-Floating Hypoid
Rear Axle Oil Capacity
..____,,...,,,...,.,..,............,,..,,..,,................................................. 2 l/2 7’.Ring and Pinion Gear Set Type
. . . . . . . . . . . . . . . . . .._................................................................Hypold
Axle Ratios

REAR AXLE49.23
Adjusting end Fitting SpecificationsPinionBearingPreloadWith
NewBearings. . . . . . . . . . . . . . . . . . . . . . . . . .7-13Lb.In.
Preload With Reused Bearings
__.._..I...................,.................,,...................,,............ 5-8 Lb.In.
Pinion Depth Setting
.002” to -.OOl’ from pinion marking using following selective shims:
Number of Notches
Thickness In.in Circumference.0097Flattened on One Side
.00980
.01081
.01182
.01283
.01384
.01485Clearance Between Differential Side Gears and Case Max.
,000” on the Opel 1900 andManta and
,006” on the GT using the following selective shims:
Thickness In.
1900
,039.04
1,043,045,047,049.05
1,053,055
GT
.0394
.0433
.0473Number of Notches
in Circumference
0
1
2
.05123Max. Permissible Axle Shaft Bearing Seat Radial Runout
.._......................................... ,002”Max. Permissible Rear Axle Shaft Flanze Lateral Runout . .
,004” at Lareest Flange Dia.
Max.Permissible Lateral Ring Gear R&out
._.._,,.........._.....,........................... T . . . . . . . . . . . ...” ,003”RingGearandDrivePinionBacklash
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .,004”-.008”
Differential Side Bearing Preload New, Bearings
- 20-30 Lb.In.; Used Bearings - lo-20Lb.In., using following selective shims:
Thickness In..0059.0069
.0079
.0089
.0098
.0108
.0197
.0433Number of Notches
in Circumference
0
1
;
4
5
8
7
Torque SpecificationsUse a reliable torque wrench. Specifications are for clean and lightly-oiled
threads.

49- 241973 OPEL SERVICE MANUAL
Torque
Lb.Ft.
1.9Nut and BoltPropshaft to Drive Pinion Shaft Extension Flange
......11
NutFlange
toDriveShaftExtension........................................87
BoltRing Gear to Case................................................................
BoltSideBearingCaptoCarrier.............................................i;
BoltDifferentialHousingCover.................................................22
NutTrackRodAttaching(GT)....................................................40
Nut and BoltStabilizer
RodtoRearAxleShackle................................25
BoltStabilizer Rod to Body........................................................15
NutTrack Rod to Rear Axle (Opal1900 & Manta)..............76
NutTrack Rod to Side Member (Opel 1900 & Manta)......22
10 MM Bolt Nut
....................................................................................................................368 MM Bolt Nut
......................................................................................................................156 MM Bolt Nut
........................................................................................................................5

DIFFERENTIAL COVER AND
SIDE BEARING CAPCOVER GASKET
DRIVE PINIONSlDE,BEARlNG /; GEAR REAR PINION BEARINGx
\PRELOAD NUT, DIFFERENTIAL CASE
SIDE GEAR
PINION GEAR
THRUST WASHER
AXLE SHAFT
BEARING RETAINER
FLAT WASHER
TORQUE TUBE40.37PRdPELLER SHAFT
Figure 48-37 Exploded View Rear Axle Assembly

MM Inches.Ol.ocQ4
.02.ooot?
.03.OOlZ
.04.0016
.05.0020
.06.0024
.07.0028
.08.0032
.09.0035
.lO.0039
.ll.0043
.12.ow7
.I3.0051
.14.0055
.15.0059
.16.OM3
.17JO67
.18.0071
.19.0075
.20JO79
.21.0083
.22.0087MM InchesMM InchesMM InchesMM InchesMM Inches
23.0091A4.0173.65.025637.03439.354324
.0095.45.0177.66II260233.034710.3937
.25Al098.46.0181.67.0264.89.0350
.26.0102.47.0185.68.0268.90.035411.4331
.27.0106.48.0186.69~3272-12.4724
.28.OllO.49.0193.70.0276.91.035813.5118
.29.0114.50.0197.92I136214.5512
.30.0118.71.0280.93.036615.5906-
[email protected]
.31.0122.52.0205.73.0287.95.037417.6693
.32.0126.53.cRo9.74.0291.96.037818.7087
.33.0130.54ml3*75*0295.97.038219.7480
.34.0134.55.0217.76SE’99.98.038620.7874
.35.0138.56.0221.77.0303.99a390
.36.0142.57.0224.78.03071.00.039421.8268
.37.0146.58.0228.79.031122.8661
.38.0150.59.023230.03151.039423.9055
.39.0154.60.02362.078724.9449
.40.0158.81.03203.118125.9&13
22.0323
4.1575261.0236
.61.024033.03275.1969271.0630
.41.0161.623244.&I.0331
6.2362281.1024
.42.0165.63.0246.85.03357.2756291.1417
.43.016954.0252.86.03398.3150301.1811
* (one MM = .0394”; one inch = 25.4 MM)4538
Figure 48-38 Conversion Table
- Millimeter to Inch Equivalent

IREAR AXLE48.27J-21691-6
J-22935
J-22936
J-22919J-22931J-8872J-2241-1 I J-7818
J-22938J-24093
J-22937
J-22588Figure
48.39 Differential Special Tools

BRAKES
GROUP 5
Section
5A
5B
5C
Title
Brake Booster and
Master Cylinder
Disc Brakes
.._.__.._____
Drum Brakes. . . . . . . . . . . . .
Page No.
5A- 2
5B-10
5C-22