oil OPEL MANTA 1973 Service Manual

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.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.

7C-1201973 OPEL SERVICE MANUAL
4. Inspect the secondary valve spring for distortion
or breakage.
5. Clean in solvent, air clean, and blow out all oil
passages. Inspect all oil passages, valve bores for
nicks, burrs or varnish in governor body. Replace if
necessary.6. Install roll pin flush to
,010” below the front face.
7. Install primary valve in governor placing the small
portion of the valve in
first. Use liberal amount of
transmission fluid. There is no spring for the primary
valve.
8. Install secondary valve with small spool portion of
valve in
first.9. Install secondary valve spring.
10. Depress secondary valve spring with small screw
driver and install retainer.
Disassembly, Inspection and Reassembly of
Governor Hub1. Inspect the three oil seal rings. See Figure
7C-189.Figure 7C.189
2. Remove governor hub oil screen. Inspect screen
and clean with solvent and air dry. Replace if neces-
sary. See Figure 7C-191.
3. Install oil screen flush to governor hub.
4. Inspect governor hub splines for cracks or chipped
teeth in splines. Replace governor hub if required.Figure 7C-191
Disassembly, Inspection end Reassembly of
Extension Housing1. Inspect extension housing for damage. Replace
housing if necessary.
2. Inspect parking
paw1 and spring for damage. Re-
place if necessary.
3. If lubricant leakage was noted prior to removal ofU-Joint from extension housing, extension housing
rear seal should be replaced.
4. Use screw driver to pry out extension housing seal.
5. Inspect extension housing bushing. If worn, scored
or damaged, bushing can be removed with remover
and installer tool J-21424-9 used with driver handle
J- 8092. See Figure
7C-192.6. Clean extension housing of dirt and foreign mat-
ter. Install new extension housing bushing using
remover/installer tool J-21424-9 with driver handle
J- 8092. Bushing must be installed flush to shoulder
of exi:ension housing. See Figure 7C-192.
7. Install new extension housing seal using installer
tool
Jo-21426. See Figure 7C-193.
Disassembly, Inspection and Reassembly of Servo
Piston1. Remove servo piston apply rod
2. Holding servo piston sleeve at flat portion of sleeve
with wrench, loosen the adjusting bolt lock nut and
remove. See Figure
7C-194.

7. Remove accumulator piston, oil ring, and spring.
See Figure 7C-200.ACCUMULATOR PISTON
Figure 7C-200AUTOMATIC TRANSMISSION 7C-123
8. Inspect accumulator oil ring for damage or edge
wear and piston for damage. Replace if necessary.
For steps 9 through 21 refer to Figure 7C-201.9. Remove 1-2 Shift control valve retaining pin, l-2
shift control valve sleeve, control valve, 1-2 shift
valve spring and valve. It may be necessary to
remove burrs in valve body bore made by retaining
pin prior to removal of the sleeves and valves.
10. Remove the 2-3 Shift control valve retaining pin
and sleeve. Also, remove the 2-3 shift control valve,
spring seat, spring and 2-3 shift valve.
11. Remove the 3-2
,control valve retaining pin and
plug. Remoye 3-2 control valve spring and control
valve.12. Remove the detent pressure regulator valve re-
taining pin, spring, and detent pressure regulator
valve.13. Remove the high speed downshift timing valve
retaining pin and spring and remove valve.
1.RETAINING PIN
2.1-2 SHIFT CONTROL VALVE SLEEVE
3.1-2 SHIFT CONTROL VALVE
4. l-2 SHIFT CONTROL VALVE SPRING5.1-2 SHIFT VALVE
6.RETAINING PIN
7.2-3 SHIFT CONTROL VALVE SLEEVE
8.2-3 SHIFT CONTROL VALVE9.2-3 SHIFT CONTROL VALVE SPRING
IO. 2-3 SHIFT CONTROL VALVE SPRING SEAT
11.2-3 SHIFT VALVE
12.1-2 ACCUMULATOR VALVE SPRING13.1-2 ACCUMULATOR VALVE
14.RETAINING PIN
15.1-2 ACCUMULATOR VALVE PLUG16.RETAlNlNG PIN
17.3-2 CONTROL VALVE PLUG18.3-2 CONTROL VALVE SPRING
d 28 29 31 32 33uu44ucBBt?a~~19. 3-2 CONTROL VALVE
20. REVERSE CONTROL VALVE
21. MANUAL LOW CONTROL VALVE
22. MANUAL LOW CONTROL VALVE SPRING
23. RETAINING PIN
24. RETAINING PIN
25. DETENT PRESSURE REGULATOR VALVE SPRING
26. DETENT PRESSURE REGULATOR VALVE
27. MANUAL VALVE
28. LOW SPEED DOWNSHIFT TIMING
VALVE SPRING
29. LOW SPEED DOWNSHIFT TIMING VALVE
30. RETAINING PIN
31. TIMING AND CONTROL VALVE PLUG
32. HIGH SPEED DOWNSHIFT TIMING VALVE
33. HIGH SPEED DOWNSHIFT TIMING
VALVE SPRING
34. RETAINING PIN
7c-201Figure 7C-201 Valve Body
- Exploded View

7C.1241973 OPEL SERVICE MANUAL
14. Remove the downshift timing valve plug retain-
ing pin and remove downshift timing valve plug.
Remove the low speed downshift timing valve and
spring.
15. Remove the manual low and r&erse control
valve retaining pin. Remove the spring and the
manual low control valve and the reverse control
valve.
16. Remove the l-2 accumulator valve retaining pin
and remove the l-2 accumulator valve plug, l-2 ac-
cumulator valve and spring.
17. A clean work area which is free of dirt and dust
should be used to inspect, clean and install the valves
in the valve body. Handle valve components with
clean hands and tools. Since most valve failures are
caused initially by dirt or other foreign matter pre-
venting a valve from functioning properly, a
thorough cleaning of all the components with a
cleaning solvent is essential. Do not use paraffin toclean out the valve body passages and valve bore.
Compressed air may be used to blow out the pas-
sages.18. Inspect each valve for free movement in its re-
spective bore in
t.he valve body. If necessary, use
crocus cloth to remove small burrs on a valve. Do
not remove the sharp edges of the valves as these
edges perform a cleaning action within the bore.
19. Inspect the valve springs for distortion or col-
lapsed coils. Replace the entire valve body assembly
if any parts are damaged.
20. Inspect the transfer plate for dents or distortion.
Replace transfer plate if necessary.
21. Reassemble the valves, springs, plugs and retain-
ing pins in their proper location and order into the
valve body using a liberal amount of transmission
fluid. See the spring data chart which includes the
spring identification sizes in the event springs have
been disarranged.
LocationApplication
PumpPressureRegulator Valve....................................................
PumpPrimingValve
...........................................................
.............Valve Body1.2ShiftValve......................................................................
Valve Body2-3ShiftValve......................................................................
Valve BodyDetentPressureRegulatorValve......................................
Valve BodyHigh-Speed Timing Valve....................................................
Valve BodyLow-Speed
TimingValve....................................................
Valve BodyReverse and Low Control Valve
........................................
CSSDetentValve..........................................................................
Valve Body1-2 Accumulator Valve........................................................
Valve Body3-2Control
Valve..................................................................
Gov. BodySecondary
Governor Valve................................................
Valve BodyAccumulator Piston
..............................................................
CaseServo Return..........................................................................SHVOServoCushion
........................................................................
Clutch PackClutchReturn(All)................................................................ SPRING IDENTIFICATION CHART
FreeOuter
HeightDiameter
2.756
,7601.043
,3202.467
,7201.769
,7001.625,474
1.349
,4061.380,406
1.343
,4062.569
,6751.072
,5201.853
.4061.317
,4061.9171.224
2.2401.850
1.0391.267
1.050
,42422. Install spring and accumulator piston in valve
body.
23. Compress accumulator piston with C-clamp and
install retaining ring.
24. Install new valve body gasket.2. Inspect and clean oil passages with cleaning sol-
vent and air.
3. Check for good retention of band anchor pins.
25. Bolt the transfer plate and gasket to the valve
body. Torque to 6-8 lbs. ft.
Disassembly, Inspection and Reassembly of Case
1. Inspect case for damage. See Figure
7C-202.4. Inspect all threaded holes for thread damage.
5. Inspect detent valve and modulator valve bores for
scratches or scoring.
6. Inspect case bushing inside of case at rear. If
da-maged, remove bushing with remover and installer
tool J-23 130-3 and driver handle J-8092. See Figure
7C-203.

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.

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.