clutch OPEL GT-R 1973 Manual PDF

712.1081973 OPEL SERVICE MANUALCHSJ
351. RETAINING PIN
72. PRESSURE REGULATOR BOOST VALVE SLEEVE
3. PRESSURE REGVLATOR BOOST VALVE
4. PRESSURE REGULATOR VALVE SPRING SEAT
5. PRESSURE REGULATOR VALVE SPRING
6. PRESSURE REGULATOR VALVE
7. OIL PUMP BODY
8. OIL PUMP PRIMING VALVE, SPRING 8 SPRING SEAT
16. Remove reverse clutch piston.
17. Remove priming valve from oil pump body by
lightly tapping with a drift through the hole at the
rear of oil pump. (Only if diagnosis requires removal
or if excessive dirt has passed through transmission.)
18. Pressure regulator and boost valve may be
removed by using a pari of wire cutters to remove the
retaining pin. Due to the difficulty of removing the
retaining pin, it is not recommended that the pres-
sure regulator valve and boost valve be disassembled
during overhaul, unless it was determined by oil
pressure checks to have been malfunctioning prior to
tear down.
19. Remove pressure regulator boost valve sleeve,
spring, pressure regulator valve and two washers. See
Figure
7C-147.20. Inspect and if necessary replace the oil pump hub
bushing by threading a 3/4” standard pipe tap such
as tool J-23130-5 into bushing. See Figure
7C-148.Figure 7C-148

AUTOMATIC TRANSMISSION 7C-109
Figure 7C-149
21. Using a drift on tap, press out oil pump bushing
with arbor press. Use rag or cloth to protect oil pumpface.22. Install new oil pump hub bushing with arbor
press using tool J-23130-1. See Figure
7C-149. Clean
pump body, including all holes and pockets
thoroughly. With oil pump shaft hole “A” facing
downward, scribe an aligning mark on oil pump
shaft inner diameter at the center of the oil groove
to the right of hole “A”. Scribe mark on outer edge
of bushing through the centers of the small and large
drilled holes “B”. Place bushing into oil pump shaft
with small hole up, and align scribe marks on bush-
ing with those made in oil pump shaft. Use arbor
press to drive bushing into oil pump shaft until
seated in the bore. Care must be taken so that bush-
ing is pressed in straight, using the scribe marks as
a guide until firmly seated.
23. Inspect and thoroughly clean the pressure regula-
tor and priming valve assemblies. Immerse all valves
in transmission fluid before installing in bores.
24. Install pressure regulator valve in oil pump body
bore. See Figure
7C-150.25. Install pressure regulator valve, two spring seats,
spring, boost valve and sleeve in oil pump body bore.
26. Depress pressure regulator boost valve sleeve un-
til backend lines up with pin hole and insert pin to
XWP$.27. Install priming valve assembly from front face of
pump. Priming valve retainer should be pressed in
flush with surface of oil pump body. See Figure 7C-
151.28. Inspect oil pump hub oil seal rings. Replace if
damaged or side wear is noted. See Figure
7C-152.29. Inspect reverse clutch piston for damage, Re-
place if necessary.
Figure
7C-150

7C-1101973 OPEL SERVICE MANUALHSEAL
REVERSE CLUTCH
Figure
7C-151Figure 7C-153Figure
7C-15230. Install new oil seals on reverse clutch piston. See
Figure
7C-153.31. Install reverse clutch piston onto rear face of oil
pump using liberal amount of transmission fluid. See
Figure
7C-154.32. Inspect reverse clutch piston springs. Evidence of
extreme heat or burning in the area of the clutch may
have caused the springs to take a heat set and would
justify replacement of the springs.
33. Install the twenty-four reverse clutch piston re-
turn springs.Figure
7C-15434. Install retaining seat.
35. Compress return springs using second and re-
verse clutch piston spring compressor tool J-2590-12
with adapter J-21420-1. Care should be taken not to
damage retainer should retainer catch in snap ring
groove. See Figure 7C-155.
36. Install snap ring using snap ring pliers such as
J-8059. See Figure 7C-155. Do not air check reverse
clutch as the clutch is not complete and damage to
the return spring retaining seat may occur.

AUTOMATIC TRANSMISSION 7C-111
OIL PUMP /’ASSEMBLY
ASPklNG
I(ETAINERSNAP RING
PLIERS
h7C146
Figure 7C.15537. Turn oil pump and reverse clutch assembly so
that oil pump face is facing up.
38. Install oil pump gears using the location mark
made before disassembly.
39. Check the end clearance of both gears to the oil
pump face. Clearance should be between
.0005 to
.0035. See Figure 7C-156.Disassembly, Inspection and Reassembly of Second
Clutch
1. Remove ring gear retaining ring from second
clutch drum. See Figure X-157.
GEAR
Figure
7C-1572. Remove ring gear. See Figure
7C-158.
SECOND CLUTCH DRUM
:-157Figure
7C-15641. Replace the oil pump assembly if the end clear-
ance is not within specifications.Figure 76.158
3. Remove second clutch spacer plate retaining ring.
4. Remove second clutch spacer plate. See Figure7c- 159.

7C-1121973 OPEL SERVICE MANUALSECOND CLUTCHSPACER
----IFigure 7C-159
5. Remove second clutch steel and composition
plates. The plates should be kept in the same se-
quence as they were installed in the clutch. See Fig-
ure 7C- 160.
Figure 7C-160
6. Remove second clutch assembly to third clutch
assembly bronze thrust washer. See Figure
7C-161.7. Install second and reverse clutch spring
cotnpres-sor tool J-2590-12 with adapter J-21420-1 on second
clutch piston return spring retainer and compress
second clutch piston return springs.
SECOND TO THIRD CLUTCHFigure
7C-1618. Remove snap ring using snap ring pliers such as
J- 8059. See Figure
7C-162.Figure 7C-162
9. Remove second clutch retaining seat and 22 return
springs.
10. Remove second clutch piston.
11. Inspect second clutch piston. See Figure
7C-163.If piston is damaged or if check ball falls out upon
inspection, replace piston. Install two new piston lip
seals.

AUTOMATIC TRANSMISSION 7C-113
12. Inspect the piston return springs. Evidence of
extreme heat or burning in the area of the clutch may
have caused the springs to take a heat set and would
justify replacement of the springs.
Figure 7C-16313. Inspect second clutch hub bushing for scoring or
wear.14. If necessary, remove second clutch hub bushing
using remover and installer J-23130-6 with driver
handle J-8092. See Figure 7C-164.
P-J-6092
SECOND CLUTCH
DRUM
iJ:23130-6Figure
7C-16415. Clean in solvent to remove any foreign matter.
Install new second clutch hub bushing using tool
J-23 130-6 and driver handle J-8092. Bushing must be
driven in until tool bottoms on bench. See Figure 7C-
164.16. To install second clutch piston into second clutch
drum, use installer tool J-23080 so as not to damage
lip seal. See Figure 7C-165. Use liberal amount of
transmission fluid for ease of installation and to pre-
vent seal damage.
SECOND CLUTCHDRUM
J-23,060Figure
7C-16517. Remove second clutch piston and seal installer
J-23080.18. Install 22 springs and retaining seat on second
clutch piston.
19. Using spring compressor tool J-2590-12 with
adapter J-21420-1 on retaining seat, compress sec-
ond clutch piston return springs. Care should be
taken so that retainer does not catch in snap ring
groove and damage retainer.
20. Install snap ring with snap ring pliers such as
J-
8059.21. Install bronze thrust washer so that the tang seats
in the slot of the second clutch hub. Secure with
petroleum jelly (unmedicated).
22. Inspect condition of composition and steel plates.
Do not diagnose a composition drive plate by co/or.
A. Dry composition plates with compressed air and
inspect the composition surface for:
1. Pitting and flaking
2. Wear
3. Glazing

7C-1141973 OPEL SERVICE MANUAL
4. Cracking
5. Charring
6. Chips or metal particles imbedded in lining
If a composition drive plates exhibits any of the
above conditions, replacement is required.
B. Wipe steel plates dry and check for heat discolora-
tion. If the surface is smooth and an even color smear
is indicated, the plates should be reused. If severe
heat spot discoloration or surface scufftng is in-
dicated, the plates must be replaced.
23. Install second clutch plates into second clutch
drum with cushion plate (wave washer) first, then
steel plate, composition plate, steel plate, etc. Use
liberal amount of transmission fluid. See Figure 7C-
166.
-I
DRUM
7c-167Figure 7C-167
Disassembly, Inspection and Reassembly of Third
Clutch1. Compress third clutch sprag race and retainer
assembly retaining ring, and remove assembly from
third clutch drum. See Figure
7C-168. Third clutch
hub and input sun gear assembly will be removed at
the same time.
Figure 7C-16624. Install second clutch spacer plate into second
clutch drum. If necessary, expand spacer plate with
screw driver until ends of spacer are evenly butted
together seating tightly into drum. See Figure 7C-
159.
25. Install second clutch spacer retaining ring
26. Install ring gear into second clutch drum.
Figure 7C-168
27. Install ring gear retaining ring.
28. Air check second clutch assembly. See Figure7C- 167.2. Remove input sprag race and retainer assembly
from third clutch hub and input sun gear assembly.
See Figure
7C-169.

AUTOMATIC TRANSMISSION 7C-115INPUT SPRAG RACE
8 RETAINER ASSEMBLY/
GEAR
CLUTCH HUBFigure
7C-1693. Push sprag assembly and retaining rings from
sprag race and retainer. See Figure
7C-170.Figure
7C.17 I7. Remove snap ring using snap ring pliers such as
J- 8059. See Figure 7C-172.SPRAG RACE
-AND RETAINER
,, SPRAG ASSEMBLY
\Figure
7C-1704. Remove third clutch plates from third clutch
drum. See Figure
7C-171. The plates should be kept
in the same sequence as they were installed in the
clutch.
5. Remove input shaft thrust washer and needle
thrust bearing. See Figure
7C-171.6. Using compressor tool J-23075 on third clutch
piston retaining seat, compress third clutch piston
return springs using arbor press.Figure 7C.172
8. Remove the retaining seat and 12 return springs.
9. Remove third clutch piston from third clutch
drum. See Figure
7C-174.
10. Inspect third clutch piston return springs. have
caused the springs to take a heat set and would jus-
tify replacement of the springs.
11. Inspect check ball in third clutch piston. If ball
is missing or falls out upon inspection or piston is

7C.1161973 OPEL SERVICE MANUALDRUM
THIRD CLUTCH
PISTON
70174Figure 7C-174
damaged, replace piston. Install new lip seal on pis-
ton. See Figure
7C-175.
CHECKTHI
Figure 7C-175
12. Install new oil lip seal on input shaft inside of
third clutch drum. See Figure
7C-176.13. Inspect steel thrust washer on front face of third
clutch drum. Replace if scored or damaged. See Fig-
ure 7c-177.
14. Install third clutch piston into third clutch drum
using a
.020 music wire crimped into a piece of cop-
per tubing and a liberal amount of transmission fluidFigure 7C-176
Figure 7C-177
so that lip seal is not damaged upon installation. See
Figure
7C-178.15. Install the 12 third clutch piston return springs
onto piston.
16. Install retaining seat.
17. Using compressor tool J-23075 on retaining seat,
compress piston return springs. Care must be taken
so that retaining seat does not catch in snap ring
groove and damage retainer.
18. Install snap ring using snap ring pliers such as J-
8059.

AUTOMATIC TRANSMISSION 7C-117WIRE CRIMPED
INTO COPPERTUBING
Figure 7C-178
19. Inspect condition of the third clutch composition
and steel plates. Do not diagnose a composition
drive plate by color,A. Dry composition plates with compressed air and
inspect the composition surface for:
1. Pitting and flaking
2. Wear
3. Glazing
4. Cracking
5. Charring
6. Chips or metal particles imbedded in lining
If a composition drive plate exhibits any of the above
conditions, replacement is required.
B. Wipe steel plates dry and check for heat discolora-
tion. If the surface is smooth and an even color smear
is indicated, the plates should be reused. If severe
heat spot discoloration or surface
scutXng is in-
dicated, the plates must be replaced.
20. Install third clutch plates into third clutch drum
beginning with a steel plate, composition plate, steel
plate, composition plate, etc. Use a liberal amount of
transmission fluid.
21. Inspect thrust washer and needle thrust bearing
for damage. Replace if necessary.
22. Install thrust washer and bearing onto input
shaft. Secure with petroleum jelly (unmedicated).23. Inspect sprag assembly for wear, damage orsprags that freely fall out of cage. Inspect input sun
gear for chipped or nicked teeth or abnormal wear.
Replace part if necessary.
24. Install sprag onto third clutch hub with groove
on sprag cage outer diameter toward input sun gear.
See Figure
7C-179.Figure 7C-179
25. Install sprag race and retainer assembly over
sprag assembly. Holding input sun gear with left
hand, sprag race and retainer assembly should “lock
up” when turned with right hand in a clockwise
direction and should rotate freely when turned coun-
terclockwise. See Figure
7C-180.Figure 7C-180