wheel OPEL GT-R 1973 Workshop Manual

3E- 38 ,1973 OPEL SERVICE MANUAL
ponents and systems, and/or could result in major
repair expense. They must be replaced with one or
the same part number or with
an equivalent part if
replacement becomes necessary. Do not use a
re-
placement part of lesser quality or substitute design.
Torque
values must be used as specified during reas-
sembly to assure proper retention of these parts.On installation, make sure steering wheel spokes
point downwards and steering gear is in high point.
1. Carefully insert steering mast into universal joint
flange.
2. Loosely attach slide-off base attaching nuts at un-
derside of instrument panel.
3. Attach steering mast jacket at front of dash, using
a notched hex nut.
4. Torque nuts at slide-off base to II
lb.ft.5. Tighten screw at steering mast clamp to 22
lb.ft.6. Reconnect wires to directional signal switch and
ignition switch.
7. Reconnect battery.
REMOVAL AND INSTALLATION OF
STEERING WHEELThis procedure may be performed with the steering
column assembly either removed or installed in the
car.
Removal
1. Disconnect battery.
2. Pry off horn cap and remove wires from cap. See
Figure
3E-3.3. Bend lockplate tabs down and take off steering
shaft nut and lockplate.
4. Install steering wheel remover J-21686 as shown
in Figure
3E-9 and pull off steering wheel.
Installation1. Before installing steering wheel, lubricate return
pin and sliding area on directional signal switch re-
turn cams and horn contact ring.
2. Make sure that clamp bolt in steering shaft flange
is on top.
3. Make sure notch on steering shaft face is in hori-
zontal position.Figure
3E-9 Removing Steering Wheel
4. With the steering wheel centered, place the steer-
ing wheel onto the steering shaft.
5. Install steering wheel lockplate and nut. Torque to
11
lb.ft.
CAUTION:
This steering wheeI to steering shaft fas-
tener is an important attaching part in that it could
affect the
performance of vital components and sys-
tems, and/or could result in major repair expense. It
must be repked
with one of the same part number
or with an equivalent part if replacement becomes
necessary. Do not use a replacement part of lesser
quality or substitute design. Torque
values must be
used as specified during reassembly to assure proper
retention of this part.6. Bend lockplate tabs up, connect horn cap wires
and replace cable and cap.
7. Reconnect battery.
REMOVAL AND REPLACEMENT OF HORN
CONTACT RING
1. Remove steering wheel.
2. Cut off defective contact ring at wire.
3. Strip wire approximately
l/8”.4. Install new part and solder connection with resin
core solder.
5. Lubricate contact ring with lubriplate, or equiva-
lent.
6. Reinstall steering wheel.

OPEL 1900 AND MANTA STEERING COLUMN ASSEMBLY3E- 39~~~A~SEMBLY AND ~EASBEMBL~ 0~
DIRECTIONAL SIGNAL SWITCHThis procedure may be performed with the steering
column assembly removed or installed in the car.
Disassembly (Opel 1900. Manta)
1. Remove steering wheel (see paragraph above).
2. Pull off signal switch and steering and ignition
lock wire set.
3. Pull directional signal lever out of seat. Lever is
held in place by a lock ball.
4. Unscrew lower half of signal switch housing cover.
See Figure
3E-10.Figure
3E-1 1 Removing Upper Part of Signal Switch
Housing Cover
Figure 3E-10 Lower Half of Signal Switch Housing
COVSr5. Remove hex nut from steering mast jacket attach-
ment at front of dash panel. See Figure
3E-7.6. Unscrew slide-off base from underside of instru-
ment panel and remove upper part of signal switch
housing cover. See Figure 3E-
11,7. Place a thick piece of wood onto front seat and let
down steering mast jacket assembly. When doing
this, the front seat must be in its front position.
8. Centerpunch tear-off bolt for steering and ignition
lock bracket attachment. Drill a. 12 in. (3mm) diam-
eter hole, using an angular-type drill and with a bolt
remover with left-hand twist screw out bolt. See Fig-
ure
3E-12.Figure
3E-12 Removing Tear-Off Bolt
9. Remove steering and ignition lock, as well as sig-
nal switch from steering mast jacket and
foosefyattach slide-off base below instrument panel.
Reassembly (Opel 1900 - Manta)
1 When replacing a new directional signal switch,
install new bearing and snap ring in switch assembly.
2. Install signal switch, as well as steering and igni-
tion lock, to steering mast jacket. To do this, screw

3E- 40 1973 OPEL SERVICE MANUAL
on steering and ignition lock bracket using a new
tear-off bolt (hexagon head tears
ofD.
3. Disconnect slide-off base, install upper half of sig-
nal switch housing cover, and loosely reattach
slide-
off base.
4. Attach steering mast jacket at front of dash panel.
See Figure
3E-7.
5. Torque slide-off base attaching nuts to 11 lb.ft.
6. Install lower half of signal switch housing cover
and connect signal switch, as well as steering ignition
lock wire set.
7. Install steering wheel and torque nut to 11
Ib.ft.
Always use new lock plate.
DISASSEMBLY AND REASSEMBLY OF STEERING
AND IGNITION LOCK CYLINDER AND ELECTRICAL SWITCH FROM MAST JACKET
ASSEMBLY
Disassembly. GT
Disconnect the battery before proceeding.
1. Remove steering wheel.
2. Turn ignition switch to ON position.
3. Insert a suitable rod into stop pin hole on side of
steering and ignition lock (See Figure
3E-13) and
take out steering and ignition lock cylinder. 4. Remove two screws securing electrical switch to
steering and ignition lock housing and take out
switch.
Disassembly (Opel 1900 . Manta)
1. Rezmove steering wheel.
2. Unscrew split signal switch housing cover and
remove lower half. See Figure
3E-10.
3. Remove lock cylinder by pushing in lock spring of
the cylinder using a piece of wire. Cylinder must be
in the
” 1” position. See Figure 3E-14.
Figure 3E-14 Removing Lock Cylinder
Reassembly
1. On the GT reassemble electrical switch into steer-
ing and ignition
lock housing and rotate switch until:
(1) cam in lock housing recess fits into slotted hole
in rear of electrical switch, and (2) projection on
electrical switch fits into recess on lock housing.
2. On the Opel 1900
- Manta, insert lock cylinder in
the
P l* position into housing. Install lower half of
signal switch housing.
3. Reinstall steering wheel.
Figure 3E-13 Removing Ignition Lock Cylinder

OPEL 1900 AND MANTA STEERING COLUMN ASSEMBLY3E- 41
SPECIFICATIONS
Steering Column Tightening Specifications
PartLocationToraue
1b.k.Nut
Steering Wheel Retaining (1900
- Manta) .._......._...,,....BoltSteering Column Flexible Coupling (1900 - Manta) ._.,
NutSlide Off Base Attaching (1 900 - Manta) ._..,,,,,,...._,,,,,..
NutMass Jacket (1 900
- Manta) .,............,,,............,,,,,.......,,,,,
screw
Steering Mast Clamp (1900
- Manta) .,.........,.._...............1122
10::

3E- 421973 OPEL SERVICE MANUAL
GT STEERING COLUMN ASSEMBLY
CONTENTS
Subject
DESCRIPTION AND OPERATION:
DescriptionofSteeringColumn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DIAGNOSIS: (Not Applicable)
MAINTENANCE AND ADJUSTMENTS: (Not
Applicable)
MAJOR REPAIR:
RemovalandInstallationofSteeringWheel. . . . . . . . . . . .Removal and Installation of Ignition Lock
Cylinder
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal and Installation of Steering Column
Assembly
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal and Installation of Center Steering Shaft
Removal and Installation of Ignition Switch
and/or Steering Lock
.,~ ,........ ~ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal and Installation of Upper Steering
Bearing and/or Directional Signal Switch
. . . . . . . . . . . .Removal and Installation of Steering Column
Lower Bearing
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPECIFICATIONS:
Steering Column Torques
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page No.
3E-42
3E-44
3E-45
3E-45
3E-46
3E-46
3E-48
3E-49
3E-50
DESCRIPTION AND OPERATION
DESCRIPTION OF STEERING COLUMNThe Energy Abosrbing, Locking Steering .Column
assembly is used on the GT. This cohnnn is designed
to compress under impact. When an automobile is
being driven, the forward movement of the automo-
bile and the forward movement of the driver both
constitute a form of energy or force. When an au-
tomobile is involved in a frontal collision, the pri-
mary force (forward movement of the car) is
suddenly halted, while the secondary force (the
driver) continues its forward direction. A severe col-
lision generally involves these two forces
- the pri-
mary and the secondary forces. The secondaryjmpact occurs when the driver is thrust forward onto
the steering wheel and column.
The Energy Absorbing Column is designed to absorb
these primary and secondary forces to the extent thatthe severity of the secondary impact is reduced. Dur-
ing a collision, the steering column compresses and
thereby reduces its tendency to move rearward into
the driver’s compartment. A split second later when
the driver is thrown forward (the secondary impact)
his energy is also partially abosrbed by the compres-
sion characteristics of the column.
The Energy Absorbing, Locking Column assembly
may be easily disassembled and reassembled. The
serviceman should be aware that it is important that
only the specified screws, bolts and nuts be used as
designated during reassembly, and that they are
tightened to their specified torque. This precaution
will insure the energy absorbing action of the assem-
bly. Particular care should be exercised to avoid us-
ing overlength bolts as they may prevent a portion of
the assembly from compressing under impact.
Equally as important is correct torquing of all bolts
and nuts.
When the Energy Absorbing, Locking Column is

3E. 441973 OPEL SERVICE’MANUAL
Figure 3E-17 Steering Column Bracket
installed in a car it is no more susceptible to damage
through usage than an ordinary column; however,
when the column is removed, special care must be
taken in handling this assembly.Only the speufied
wheel puller should be used.When the column is removed from the car, such
actions as a sharp blow on the end of the steering
shaft laying things across or on top of the column
assembly, leaning on the column assembly, or drop-
ping of the assembly could shear or loosen the plastic
fasteners that maintain column rigidity or possibly
bend the assembly causing a binding condition.
It is
therefore important that the removal and installation
and the disassembly and reassembly procedures be
strictly followed when servicing this assembly.The steering column assembly is attached with a
bracket (A) at four points to the connecting brace
below the instrument panel. See Figure
3E-17. The
two upper bolts are designed as tear-lock-bolts. A
bolt (B) is welded to the bracket which engages in an
narrowing elongated hole. The same applies to the
upper bolt (C) of the steering column lower bearing
attachment which engages in a hole of the connect-
ing brace.
As soon as a sufficiently large secondary energy
becomes effective, the steering mast jacket slides to-
wards the front whereby the bolt (B) as well as the
bolt head (C) is additionally pushed into the respec-
tive narrowing elongated holes. Both elongated holes
are arranged so that the primary energy cannot push
the steering mast assembly into the passenger com-
partment.
The GT steering column incorporates two universaljoints to allow
~for the offset between the steering
column and the gear assembly.
The upper steering column assembly is connected to
the center steering shaft with one universal joint,
while the lower universal joint connects the center
steering shaft to the steering gear pinion shaft.
REMOVAL AND INSTALLATION
REMOVAL AND INSTALLATION OF STEERING
WHEELThis procedure may be performed with the steering
column assembly either removed or installed in the
car.Removal
1. Disconnect battery.
2. Remove horn cap.
3. Bend lockplate tabs down and remove steering
wheel nut, lockplate and washer.
4. Mark shaft and wheel hub for reassembly align-
ment.
5. Remove steering wheel using steering wheel puller
J-21686. Do not rap on end of puller in order to free
wheel from shaft as this would very likely loosen
plastic injections that maintain steering shaft rigid-
ity. Striking of underside of steering wheel to jar it

GT STEERING COLUMN ASSEMBLY3E- 45
loose must never be done. The only recommendation
for freeing frozen steering wheels is to use a penetrat-
ing lubricant.Installation1. Before installing steering wheel, lubricate return
pin and slide area on direction signal switch return
cams and horn ring contact.
2. With steering wheel properly aligned to shaft, in-
stall lockplate and nut. Torque nut to 15
Ib.ft.
CAUTION:
This steering wheel to steering shafi fas-
tener is an important attac&ng part in that it could
affect the performance of vital components and sys-
tems, and/or could result in major repair expense. It
must be
rep/aced with one of the same part number
or with an equivalent part, if replacement becomes
necessary. Do not use a replacement part of lesser
quality or substitute design. Torque values must be
used as specified during reassembly to assure proper
retention of this part.3. Bend up lockplate tab and install horn cap.
4. Reconnect battery.
REMOVAL AND INSTALLATION OF IGNITION
LOCK CYLINDER
RemovalThis procedure may be performed with the steering
column assembly either removed or installed in the
car.1. Remove steering wheel, as outlined previously in
this Group.
2. Position lock cylinder to run position.
3. Using suitable piece of wire, push in lock cylinder
retaining pin and remove lock cylinder. See Figure3E- 18.
Installation1. Insert lock cylinder into lock cylinder housing.
2. Install steering wheel, as outlined previously in
this section.
REMOVAL AND INSTALLATION OF STEERING
COLUMN ASSEMBLY
Removal1. Position steering so that front wheels are straight
ahead.Figure
3E-18 Removing Lock Cylinder
2. Loosen steering shaft upper universal joint lower
clamp bolt. See Figure
3E-19.3. Drill off heads of both tear bolts by first drilling
an 3/16 inch pilot hole and then inserting a
l/4 inch
bolt extractor to remove lockbolt.
4. Disconnect ignition (white) and direction signal
(black) wire set plugs.
5. Support steering column assembly and remove
both hex. head bolts.
6. Pull steering column assembly off center steering
shaft. Do not apply any force as plastic injections in
center steering shaft may be loosened and shaft
would then require replacement.
Installation
CAUTION:
Fasteners are important attachingparts in
that they
cooId affect the performance of vital com-
ponents and systems, and/or could result in major
repair expense. They must be replaced with one of
the same part number or with an equivalent part if
replacement becomes necessary. Do not use a re-
placement part of lesser quality or
substitute design.
Torque values must be used as specified during
reas-
sembIy to assure proper retention of these parts.1. Install steering column assembly onto steering
shaft and torque steering shaft upper universal joint
lower clamp bolt to 14
lb.ft.2. Install hex head bolts and torque to 14
lb.ft.
NOTE:
Be sure to install ground wire.

I3E. 461973 OPEL SERVICE MANUAL
Figure 3E-19 Steering Column Attachments
3. Install new tear bolts and tighten until hex
head of bolt is tom off.
4. Reconnect ignition and direction signal wire sets.
REMOVAL AND INSTALLATION OF CENTER
STEERING SHAFT
RemovalSteering shaft must be handled carefully so as not to
loosen plastic injections as shaft would then require
replacement.
CAUTION:Fasteners are important attaching parts
in that they could affect the performance of vital
components and systems, and/or could result in
major repair expense. They must be replaced with
one of the same part number or with an
equivalent part if replacement becomes necessary.
Do not use a replacement part or lesser quality or
substitute design. Torque values must be used as
specitied during reassembIy to assure proper
retention of these parts.1. Install steering shaft through bottom and position
into upper universal joint.
1. Position steering so that front wheels are straight
ahead.2. Insert shaft into lower universal joint and torque
bolt to 22 lb.ft.
2. Loosen steering shaft upper universal joint lower
clamp bolt.3. Torque upper universal joint bolt to 14
lb.ft.3. Remove steering shaft lower universal joint upper
clamp screw.
4. Carefully push center steering shaft up into steel
washer joint until lower end is free.REMOVAL AND INSTALLATION OF IGNITION
SWITCH AND/OR STEERING LOCK
Removal5. Remove steering shaft through bottom.
1, Remove ignition lock cylinder, see previous para-
graph in this section.

GT STEERING COLUMN ASSEMBLY3E- 49
4. Install ignition switch and steering lock
REMOVAL AND INSTALLATION OF STEERING
COLUMN LOWER BEARING
The following is with steering column assembly
removed.
1. Remove steering wheel.
2. Remove screws securing lower bearing housing to
mast jacket.
3. Remove steering shaft together with universal
joint and bearing and housing.
4. Remove universal joint from shaft. See Figure 3E-28.Figure 3627 Removing Upper Bearing
SERRATED SOCKET
“‘*E.Z<~lh I’
I//
11 uBEARING HOUSINGy
SE-28Figure 3E.28 Removing Lower Bearing
5. Remove bearing retainer snap ring and remove
bearing.
Installation3. Install steering shaft, together with universal joint
bearing and housing to mast jacket. Serrated socket
head screw must be installed on
tm side of steering
column assembly. See Figure 3E-2\.
1. Install bearing and bearing retainer snap ring.
2. Install universal joint and torque to 22
Ib.ft.4. Install steering wheel. On installation of steering
wheel, make sure that with flats of lower portion of
universal joint horizontal, the center steering wheel
spoke must be vertical.

13E. 50 1973 OPEL SERVICE MANUALPART
Bolt
BoltLOCATION
Steering WheelUpper Universal Joint
- Lower Clamp
Upper Universal Joint
- Hex Head
Lower Universal Joint
TORQUE
LB.FT.
15
14