gear OPEL MANTA 1973 Service Manual

AUTOMATIC TRANSMISSION 7C-1251. CASE VENT4.3RD CLUTCH7.SUCTION
2. CONVERTER OUT5MODULATOR8.LINE/3.2ND CLUTCH
6. BOOST9.REVERSEFigure 7C-202 Case Front View Oil Passage
Identification
7.
!nspect reaction sun gear drum bushing sleeve
inside case at rear for scoring. If necessary, replace
sleeve before installing rear case bushing.
8. Remove sleeve by grinding. Care must be used in
order that aluminum case is not damaged when
grinding sleeve.
9. Install new sleeve using installer tool J-23130-7
and driver handle J-8092.
10. Install new case bushing using remover and in-
staller tool J-23130-3 and driver handle J-8092.
Bushing should be installed flush with case at rear.
See Figure
7C-203.Figure 7C-2031. Drain Converter. If clutch disc material or
foreign matter has been found while draining con-
verter,
replace entire converter assembly as it can not be
cleaned properly.
2. Air check converter for leaks using converter
checking tool J-21369. Install tool and tighten. Ap-
ply 80 psi air pressure to tool. See Figure
7C-204.Figure 7C-204
3. Submerge in water and check for leaks.
4. Check converter hub surfaces for scoring or wear.
Installation of Selector Lever and Shaft1. Install new selector lever shaft oil seal in case.
Insert selector lever shaft through case from outside.
Care should be exercised so that oil seal is not da-
maged. See Figure
7C-206.2. Insert spring pin in case to secure selector lever
shaft.3. Guide selector lever over shaft and secure with
lock nut.
4. Insert parking
paw1 actuator rod from front of the
case and through hole in case at rear. See Figure 7C-
207.5. Install parking
paw1 actuator rod retaining ring.
Installation of Low Band1. Turn transmission case so that front of case is
upward.

7C-1261973 OPEL SERVICE MANUAL13
57911n-205
1. CLUTCH ASSEMBLY THRUST WASHER
2.
2ND CLUTCH ASSEMBLY TO 3RD CLUTCH
ASSEMBLY BRONZE THRUST WASHER
3. 2ND CLUTCH ASSEMBLY TO 3RD CLUTCH
ASSEMBLY STEEL THRUST WASHER
4. INPUT SHAFT TO SUN GEAR
THRUST WASHER
5. INPUT SUN GEAR ASSEMBLY BEARING
Figure 7C-205 Location2. Inspect band for cracks, flaking, burring or loose-
ness. Replace if required.
Figure 7C-2066. INPUT SUN GEAR ASSEMBLY BEARING
7. INPUT SUN GEAR ASSEMBLY TO PLANETARY
CARRIER ASSEMBLY WASHER9. REACTION SUN GEAR BEARING ASSEMBLY
10. REACTION SUN GEAR 8 BEARING ASSEMBLY
11.
RE,ACTlON SUN GEAR 8 DRUM
ASSEMBLY THRUST WASHERof Bearings And
Washers3. Place band in case and locate band onto the anchor
pins in case. See Figure
7C-208.Figure 7C-207

AUTOMATIC TRANSMISSION ?C-127
INPUT SHAFT
Figure 7C-208
1. Place needle thrust bearing race on rear of
case around the case bushing. Secure with petroleum
jelly (unmedicated).
2. Place needle thrust bearing on race. See Figure 7C-
209. Secure with petroleum jelly (unmedicated).
Figure 7C-2093. Insert reaction sun gear and drum into band with
reaction sun gear facing upward.
4. Place needle bearing on first then race on front
face of reaction sun gear. See Figure
7C-210. Secure
with petroleum jelly (unmedicated).Figure
7C-2 10
Installation of Output Shaft and Planetary Carrier
1. Install input sun gear to planetary carrier washer
and bearing into carrier. Secure with petroleum jelly
(unmedicated).
2. Insert output shaft and planetary carrier assembly
from front of case to spline with reaction sun gear.
See Figure
7C-211.Figure
7C-2 1 1Installation of 2nd and 3rd Clutch Assemblies Into
Case
1. With second clutch assembly on bench, align sec-
ond clutch drive plates in second clutch drum.

7C-1281973 OPEL SERVICE MANUAL2. Insert third clutch drum and input shaft through
top of second clutch drum seating third clutch drum
splines into the second clutch plate splines. See Fig-ure x2- 212.
Figure 7C-2 123. Holding second and third clutch assemblies by the
input shaft, lower into transmission case, indexing
ring gear in second clutch drum with long planetary
pinion gear teeth. See Figure
7C-213..----INPUT
SHAFTInstallation of Reverse Clutch
1. Inspect condition of the composition and steel
;:;;;.Do not diagnose a composition drive plate by
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 scuffing is in-
dicated, the plates must be replaced.
2. Install the steel reaction plate into the case. See
Figure 7C-214.
Figure 7C-2 143. Install reverse clutch steel plate, composition
plate, steel plate, composition plate, etc., into case.
Use a liberal amount of transmission fluid.
Figure 7C-213

AUTOMATIC TRANSMISSION 7C-129
4. Install reverse clutch cushion plate (wave washer)2. Insert guide pin into oil pump for alignment of
into case.converter housing and lower housing onto pump.Determining Selective Washer Size
1. Place gauging tool J-23085 on case flange andagainst input shaft. See Figure
7C-215.3. Install new oil seal washers on converter housing
to oil pump bolts, and loosely install bolts into con-
verter housing.
4. Use convkrter housing to oil pump aligning tool J-23082 to align converter housing to pump. See Fig-
ure
7C-216. Tool should bottom on oil pump gear.
Figure 7C-2 152. Loosen thumb screw on tool to allow inner shaft
to drop on second clutch drum hub.
3. Tighten thumb screw and remove tool J-23085.
4. Place selective washer removed from transmission
against inner shaft of tool J-23085. Selective washer
should be flush with top face of shaft. If not flush,
select next larger or smaller washer until correct size
is obtained. The washer selected should be exactly
flush or slightly below inner shaft for correct end
play in transmission. Selective washer removed from
transmission may be oil soaked and discolored.
CObX
ID
Yellow
Blue
Red
BVSNIl
GPX3”
Black
Thickness,070.,074,076.,080
.08 l-.085,086.,090,091.,095
,097.,101
Installation of Converter Housing, Oil Pump and
Reverse Clutch Assembly1. Turn case so that bottom of transmission is facing
upward.
1. Install oil pump wear plate onto oil pump.2. Slide governor hub along output shaft and seat
Figure 7C-2 165. Tighten the five bolts. Torque to
13-17 Ibs. ft. and
remove aligning tool l-23082.
6. Install new converter housing to case rubber oil
seal.7. Install new pump flange gasket.
8. Place selective washer, previously determined,
onto the oil pump shaft and retain with petroleum
jelly (unmedicated).
9. Install two guide pins in case and lower converter
housing and oil pump into case. See Figure
7C-217.10. Bolt converter housing to case using new oil seal
washers on all seven bolts. Torque to 13-17 lbs. ft.
I I. Check for correct assembly by turning input shaft
by hand.
Installation of Governor Assembly

7C-130
1973 OPEL SERVICE MANUAL
Figure 7C-2 17
into case. See Figure 7C-218. Use liberal amount of
transmission fluid on oil seal rings.
GOVERNOR
HUBFigure
7C-2 183. Install snap ring over output shaft using snap ring
pliers such as J-8059. See Figure
7C-219.4. Install new governor body gasket.
5. Bolt governor body to governor hub. Torque to 6-8
lbs. ft. The two governor valves should move freely
after governor body is torqued.
6. Install speedometer drive gear retaining clip into
output shaft. See Figure
7C-220.Figure 7C-219
Figure 7C-220
7. While depressing retaining clip, slide speedometer
gear over output shaft and install gear and retaining
clip.
Installation of Extension Housing
1. Install new extension housing gasket.
2. Slide extension housing over output shaft and
align holes.
3. Align parking
paw1 shaft into extension housing.

AUTOMATIC TRANSMISSION 7C-1314. Bolt extension housing to rear of case. Torque to
20-30 Ibs. ft. See Figure
7C-221.
Figure 7C-22
1
Installation of Speedometer Driven Gear1. Install speedometer driven gear and housing into
extension housing. See Figure
7C-222.Figure 7C-222
2. Install speedometer driven gear housing retainer
into slot provided in speedometer driven gear hous-
ing. Bolt retainer to extension housing. Torque to
6-Slbs. ft. See Figure
7C-223.
installation of Detent Valve, Modulator Valve,
Modulator Assembly1. inspect detent valve sleeve oil seal and replace if
necessary.Figure 7C-223
2. Install detent valve, sleeve, spring, and spring seat
into case bore using liberal amount of transmission
fluid.
3. Depress detent valve spring and insert spring pin
to secure detent valve assembly. Detent valve sleeve
must be installed with slots facing oil pan. Care
should be taken so that spring pin is inserted into the
groove provided in sleeve and not into one of the oil
passage slots in the sleeve.
4. Install modulator valve and sleeve into case with
small end of modulator valve first.
5. Using new modulator assembly gasket, install
plunger and thread modulator into case and tighten
to
12-15 Ibs. ft. using tool J-23100. See Figure 7C-
224.
Installation and Adjustment of ServoAdjustment of servo can be performed with trans-
mission in vehicle.
1. Install servo apply rod, spring and piston into case,
using liberal amount of transmission fluid.
2. Compress servo piston spring using compressor
tool J-23075, lightly tapping servo piston while com-
pressing until piston is seated to avoid damage to the
oil seal ring.
3. Install servo retaining ring. See Figure
7C-225.Remove compressor tool J-23075.

AUTOMATIC TRANSMISSION 7C-135
becomes necessary to check the fluid level, the trans-
mission may be checked at room temperature (70
degrees F.) as follows:
1. With manual control lever in Park position start
engine. DO NOT RACE ENGINE. Move manual
control lever through each range.
2. lmmediately check fluid level with selector lever
in Park, engine running, and vehicle on LEVEL sur-
face.At this point, when a reading is made, fluid level on
the dipstick should be I/4” below the “ADD” mark.
3. If additional fluid is required add fluid to bring
level to
l/4” below the “ADD” mark on the dip-
stick.If transmission fluid level is correctly established at
70 degrees F. it will appear at the “FULL” mark on
the dipstick when the transmission reaches normal
operating temperature (180 degrees F.) The fluid
level is set
l/4” below the “ADD” mark on the
dipstick to allow for expansion of the fluid which
occurs as transmission temperatures rise to normal
operating temperature of 180 degrees F.
Do not overfill, as foaming and loss of fluid through
the vent pipe might occur as fluid heats up. If fluid
is too low especially when cold, complete loss
of’drive may result which can cause transmission fail-
ure.
2.Draining oilpan and rep/a&g strainer assembly.
(a) Raise car on hoist or p/ace OnJxk stands, and
provide container to collect draining fluid.
(b) Remove oil pan and gasket. Discard gasket.
(c) Drain fluid from oil pan. Clean pan with solvent
and dry thoroughly with clean compressed air.
(d) Remove strainer assembly, strainer gasket and
discard.
(e) Install new oil strainer gasket. Install new strainer
assembly.
(f) Install new gasket on oil pan and install pan.
Tighten attaching bolts to 7-10 lb. ft.
(g) Lower car and add approximately three (3) pints
of transmission fluid through filler tube.
(h) With manual control lever in Park position, start
engine. DO NOT RACE ENGINE. Move manual
control lever through each range.
(i) Immediately check fluid level with selector leverin Park, engine running, and vehicle on LEVEL
sur-
face.(i) Add additional fluid to bring level to
l/4” below
the “ADD” mark on the dipstick. Do not overfill.
3.Adding Fluid to Fill Dry Transmission and Con-
verter Assembly
The fluid capacity of the Opel Three Speed Auto-
matic transmission and converter assembly is ap-
proximately IO-l/2 pints, but correct level is
determined by the mark on the dipstick rather than
by amount added. In cases of transmission overhaul,
when a complete fill is required, including a new
converter proceed as follows:
(a) Add approximately 10-l/2 pints of transmission
fluid through tiller tube.
The converter should be replaced on any major fail-
ure, such as a clutch or gearset, and an excessive
amount of foreign material is indicated in the pan. If
installation of a new converter is not required add
approximately five (5) pints of transmission fluid.
(b) With manual control lever in Park position start
engine and run at 1000 RPM. DO NOT RACE EN-
GINE. Move manual control lever through each
range.
(c) Immediately check fluid level with selector lever
in Park, engine running, and vehicle on LEVEL
sur-
face.(d) Add additional fluid to bring level to
l/4” below
the “ADD” mark on the dipstick. Do not overfill.
Opel Three Speed Automatic Transmission Towing
Instructions
If an Opel equipped with an automatic transmission
must be towed, the following precautions must be
observed:
The car may be towed safely on its rear wheels with
the shift lever in neutral position at speeds of 35 miles
per hour or less under most conditions.
However, the drive shaft must be disconnected or the
car towed on its front wheels if:
a. Tow speeds in excess of 35 mph are necessary.
b. Car must be towed for extended distances (over 50
miles).
c. Transmission is not operating properly.
If car is towed on its front wheels, the steering wheel

7C-1361973 OPEL SERVICE MANUALshould be secured to keep the front wheels in a
straight-ahead position.sand,. mud, or snow, move the selector lever from
“D” to “R” in a repeat pattern while simultaneously
applying moderate pressure to the accelerator. DoRocking Carnot race engine. Avoid spinning wheels when trying
If it becomes necessary to rock the car to free it fromto free the car.
Model DesignationsTrans.
converterReverse Clutch
ModelAssemblyPlates Required2nd Gear
Clutch3rd Gear Clutch
Plates Required
Plates RequiredOpel
1900
OG
GT
CIHInformation
Drive
(Composition Faced:
Drive3Drive3
Green
(Composition
Faced)(CompositionFaced)
Dot ofDriven (Steel)4Driven (Steel) 4
Driven (Steel) 4
PaintWaved1Waved1Waved.1Pressure1Pressure1Pressure1-.
Bolt Torque Specifications
Location
Oil Pan to Case......................................................................Transfer Plate to Valve Body............................................
ReinforcementPlatetoCase..............................................
ValveBodytoCase..............................................................
ServoCovertoCase............................................................
Modulator Assembly............................................................
ConverterHousingtoOilPump........................................
Converter Housing to Case................................................
Selector Lever Jam Nut......................................................
Governor Body to Governor..............................................
ExtensionHousing to Case................................................
Servo AdjustingBolt Lock Nut..........................................
Planetary Carrier Lock Plate..............................................
OilPressureCheckPlug......................................................
Flex Plate to Crankshaft......................................................
Converter to Flex Plate........................................................
ConverterHousingtoCylinderBlock..............................
intermediate Selector Lever to Console
Selector Lever Shaft........................................................
Rear Engine Support to Transmission
CaseExtension..................................................................
Outer Transmission Selector Lever to
TransmissionSelectorLeverShaft..............................
Oil Cooler Line Connector..................................................
Oil Cooler Line to Connector............................................
Oil Cooler Line to Oil Cooler Hose..................................
Oil Cooler Hose to Oil Cooler............................................
Torque
Lb.Ft.7-10
6-8
13.15
13.1516-1812.15
13.17
22.26
8-l 1
6-8
20.30
12.15
20.35
5-736.5
138.42
38.42
Thread
Size
5/16-18
l/6-20
5/16-18
5/16-18
5/16-18
5/16-18
5/16-18
l/4-20
3/8-l 6
18.20
18.22
13.1610-13
1 l-15
1 l-15
11.15

AUTOMATIC TRANSMISSION 75139
SPECIAL TOOLSJ-8763-01
:: J-21369
3.J-8400-1
4.J-3289-20
5.J-23130-3
6.J-8092
7.J-21359
8.J-21426
9.J-2312910. J-7004
11. J-2590-12
12. J-21420-1
13. J-23130-7
14. J-23075
15. J-23 130-S16. J-231306
17. J-23130-1
18. J-21424-9
19.J-21465-17
20.J-23080
21.J-23 130-2
22.J-23082
23.J-23085
24.J-23 100Transmission Holding Fixture
Converter Leak Test Fixture
Cape ChiselHolding Fixture Base
Rear Case Bushing Remover and Installer
Driver Handle
Converter Housing Oil Seal Installer
Extension Housing Oil Seal Installer
Converter Housing Seal Remover
- Without Disassembling Transmission
(Use With J-7004)Slide Hammer
2nd and Reverse Clutch Piston Spring Compressor
Clutch Piston Compressor Adapter
Reaction Sun Gear Drum Bushing Sleeve Installer
Servo and 3rd Clutch Piston Spring Compressor
Oil Pump Bushing Remover
2nd Clutch Drum Bushing Remover and Installer
Oil Pump Bushing Installer
Extension Housing Bushing Remover and Installer (Use with J-8092
Driver Handle)
Converter Housing Bushing Remover and Installer (Use With J-8092)
2nd Clutch Piston Seal Installer
Reaction Sun Gear Drum Bushing Installer
Converter to Oil Pump Alignment Tool
Oil Pump to 2nd Clutch Drum Gauging Tool
Vacuum Modulator Wrench