gear OPEL MANTA 1973 Owner's Manual

3D. 281973 OPEL SERVICE MANUALr
LFLEXIBLE
COUPLING
SHAFT.
NEEDLE BEARING
L
LPINION BUSHING
O-RING SEAL
Figure
3D-2 Steering Gear Assembly - End View
3D-2RACK GUIDE
rBUSHINGFigure
3D-3 Steering Gear Assembly Front View
until a resistance is felt. By threading in adjusting
screw when steering gear is set to highpoint, the
MAJOR REPAIRsintered bronze she0
l’s pushed against the rack SO
that the rack is blocked.
REMOVAL AND INSTALLATION OF STEERING
3. Back off adjusting screw
l/8 to l/4 of a turn.GEAR ASSEMBLY AND TIE RODS
4. Tighten lock nut to a torque of 43 lbs.ft.
Removal. GT5. Fill area under pinion shaft rubber boot with steer-
ing gear lubricant and slide boot into position.1. Remove rubber knee protector pad.

STEERING GEAR ASSEMBLY30-292. Loosen clamp securing flexible coupling to steer-
ing shaft.
4. Remove stop bolt (see Figure 3D-4) from under-
side of steering column (secures steering shaft bush-
ing to mast jacket), and pull steering wheel rearward
approximately three inches.
Figure
3D-4 Stop Bolt
4. Remove cotter pin located on left and right tie rod
ends and unscrew nut.
5. Using remover J-21687, press ball studs out of
steering arms (see Figure
3D-5).
IJ-21 68’Figure 3D-5 Removing Ball Stud6. Remove four attaching bolts securing steering gear
to front suspension cross member (see Figure 3D-6)
and lift off steering gear assembly and tie rods.
Figure
3D-6 Steering Gear Assembly Attaching Bolts
Removal (Opel 1900. Manta)1. Remove splash shield from lower deflector pa:
and both side members. See Figure
3D-7.nel
Figure
3D-7 Removing Splash Shield
2. Remove clamp bolt securing flexible coupling to
steering shaft. See Figure
3D-8.

3D- 301973 OPEL SERVICE MANUALFigure 3D-8 - Removing Clamp Bolt3. Remove cotter pin located on left and right tie rod
end and unscrew nut.
4. Using Tool J-21687, press tie rod ends out of
steering arms.
5. Disconnect steering gear housing from front sus-
pension cross member and remove steering gear
together with tie rods.
Installation . GTCAUTION: Fasteners are important attaching parts in
that they could 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-
sembly to assure proper retention of these parts.
1. Position steering gear on front suspension cross
member and torque attaching bolts to 18
lb.ft.2. Position tie rod ball studs in steering arms; install
nuts and torque to 29 lb.ft. Lock in position with new
cotter pins.
3. Fully turn steering wheel so that flat or cutout
surface on lower portion of steering shaft is parallel
to flexible coupling bolt hole.
4. Install the lower end of steering shaft to the flexi-
ble coupling and adjust dimension between steering
wheel hub and direction signal switch housing cover
to
l/8 and 3/32 inch. Maintain adjustment by tight-
ening flexible coupling bolt and nut to 15 lb.ft. Lock
the bolt and nut in position with lock-plate tabs.5. Reinstall stop bolt into steering column.
6. Full turn steering wheel both right and left. If any
resistance is noticeable, it will be necessary to remove
the sleering column and correct the cause.
D. Installation (Opel 1900. Manta)CAUTION: Fasteners are important attachingparts in
that they could affect the performance of vital com-
ponents and systems, and/or could result in
maJbrrepair 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 oflesser
quaky or substitute design.
Torque values must be used as specified during reas-
sembly to assure proper retention of these parts.
1. Prior to installation, set steering gear to high
point. The steering wheel spokes point downwards in
an oblique angle. The elongated cutout of the lower
steering mast must coincide with the clamp bolt hole
of the pinion flange.
2. Position steering gear on front suspension cross
member and torque attaching bolts to 29 lb.ft.
3. Position tie rod studs in steering arms. Install nuts
and torque to 29
Ib.ft. Lock in position with new
cotter pin.
4. Install the lower end of the steering shaft to flexi-
ble coupling and torque clamp bolt to 22
lb.ft.5. Attach guard plate to both side members and
lower deflector panel.
DISASSEMBLY AND ASSEMBLY OF
STEERING GEAR ASSEMBLY WITH TIE RODS
Disassembly - GT1. Carefully clamp gear assembly in soft jaw vise and
slip clamps and rubber bellows off gear housing to
expose area where ball joint screws into rack.
2. Bend up round edges of lockplates from tie rod
ball studs and disconnect tie rod ball studs from rack.
See Figure
3D-9). It is important that rack be held
secure with open end wrench to prevent damage to
rack teeth.
3. Loosen adjusting screw lock nut; remove adjusting
screw from steering gear housing, and take out thrust
spring and sintered bronze shell. See Figure
3D-11.4. Rotate gear assembly in vise so that pinion shaft
portion of assembly is held by vise, and remove pin-
ion nut, flat washer, and special washer.

STEERING GEAR ASSEMBLY3D- 31
Figure 3D-9 Removing Tie Rods
5. Remove pinion shaft from gear assembly, and then
withdraw rack from gear assembly.
6. From steering gear housing remove “0” rings
from retainer and pinion bushing. Also take out
thrust washer. See Figure
3D-17.
Disassembly (Opel
1900. Manta)1. Carefully clamp steering gear assembly in soft jaw
vise.2. Disconnect left and right tie rod end from respec-
tive axial joint (locknut). See Figure
3D-10. The ball
joint of the tie rod end is maintenance-free, must not
be disassembled and has to be replaced as an assem-
bly only.
Figure 3D-10 Removing Tie Rod Ends from Axial
Joint3. Remove clamping wire and hose clamp from rub-
ber bellows. Remove bellows from steering gear
housing and axial joint. See Figure
3D-10.4. Disconnect ball stud of axial joint from rack (lock
plate, stop plate). To do this, counterhold rack with
open-end wrench to avoid damage to the teeth. See
Figure
3D-11. The axial joint is maintenance-free,
must not be disassembled and has to be replaced as
an assembly only.
Figure
3D-1 1 - Removing Axial Joint
5. Loosen adjusting screw locknut, screw out adjust-
ing screw and remove thrust spring as well as bearing
shell out of adjusting screw opening.
6. Remove sheet metal cap from steering gear hous-
ing and remove hex nut from pinion. Do not turn
pinion in end position.
7. Pull pinion and rack out of steering gear housing.
Reassembly. GT1. Clamp steering gear housing in a soft jaw vise as
shown (see Figure 3D-17) and reassemble new “0”
rings onto retainer and pinion shaft bushing. Also
install thrust washer onto pinion bushing.
Coat all moving parts during reassembly with suita-
ble steering gear lubricant. Fill long end of housing
with approximately
l-3/4 oz. steering gear lubricant.
2.. Insert long toothless end of rack into short end of
housing until rack protrudes equally (approximately
Z- 7/S inch) out of both ends of housing. See Figure3D- 13.

3D- 321973 OPEL SERVICE MANUAL
Figure 3D-13 Steering Gear Housing With Rack
Check to insure that three air channels of sintered
metal bushing (See Figure 3D-17) are not obstructed
by lubricant. If air channels are blocked, a vacuum
condition in the bellows may result during operation
of the gear assembly. Under such circumstances, the
bellows will be drawn inward and jam into the rack
teeth.
3. Reassemble pinion shaft into gear assembly so that
spline in pinion shaft meshes with twelfth tooth of
the rack. Use pinion mounting sleeve J-21712 during
installation of pinion shaft to avoid damage to “0”
ring in pinion bushing. When reassembling pinion
shaft into gear housing, be sure that pinion is so
positioned that bolt hole in pinion shaft flexible cou-
pling is on top and parallel to the rack. See Figure3D- 14..~.. ~. ..~.IN FLEXIBLE
COUPLING PARALLEL ORRIZONTAL WITH R
._..-_ - -._..-
Figure 3D-14 Installing Pinion Shaft
4. Reassemble special washer, flat washer, and new
pinion nut onto pinion shaft. Torque pinion nut to 11
Ib.ft. Do not exceed torque due to possibility ofjam-
ming gear.
5. Place sintered bronze shell into steering gear hous-
ing and fill adjusting hole with Calcium Soap No. 2.
6. Reassemble thrust spring, adjuster screw and lock-
nut on gear assembly.
Final adjustment of adjuster screw is performed after
gear assembly and tie rods are installed in car. See
Maintenance and Adjustments in this section for ad-
justment of steering gear.
7. Place rubber bellows, clamps, and new lock plates
on ball stud portion of tie rods; and screw ball studs
into rack while holding bent tab of lock plate against
flat
ton rack. Torque ball studs 43 lb.ft. See Figure
3D-9. It is important that rack be held secure with
open end wrench to prevent damage to rack teeth.
8. Bend round edges of lock plate over flat on ball
stud to lock ball stud in position. See Figure
3D-15.Figure 3D-15 Bending Lock Plate Over Ball Stud
9. Properly position rubber bellows and clamps over
tie rod and gear housing and adjust clamps so that
ends are pointing same direction as adjusting screw.
Check that bellows is not twisted and will compress
and expand properly.
Reassembly (Opel 1900 - Manta)1. Clamp steering gear housing in a soft jaw vise and
reassemble new “0” rings onto retainer and pinion
shaft bushing. Also, install thrust washer onto pinion
bushing.
Coat all moving parts during reassembly with suita-

STEERING GEAR ASSEMBLY30.33ble steering gear lubricant. Fill long end of housingbly. Under such circumstances, the bellows will be
with approximately 1 3/4 oz. steering gear lubricant.
drawn inward and jam into the rack teeth.
3. Reassemble pinion shaft into gear assembly so that
spline in pinion shaft meshes with twelfth tooth of
the rack. Use pinion mounting sleeve J-21712 during
installation of pinion shaft to avoid damage to “0”
ring in pinion bushing. When reassembling pinion
shaft into gear housing, be sure that pinion is so
positioned that bolt hole in pinion shaft flexible cou-
pling is on top and parallel to the rack. See Figure
3D-16.2. Insert long toothless end of rack into short end of
housing until rack ends (A) protrude equally out of
both ends of housing. See Figure
3D-16.Figure 3D-16
- Steering Gear Housing With Rack
Check to insure that three air channels of sintered
metal bushing are not obstructed by lubricant. If air
channels are blocked, a vacuum condition in the bel-
lows may result during operation of the gear assem-
SPECIFICATIONS
Tightening Specifications
PartLocation
BoltBolt
Nut
NutNut
Bolt
Bolt
NutNut
Nut4. Reassemble special washer, flat washer, and new
pinion nut onto pinion shaft. Torque pinion nut to 11
lb.ft. Do not exceed torque due to possibility of jam-
ming gear.
5. Place sintered bronze shell into steering gear hous-
ing and till adjusting hole with suitable steering gear
lubricant.
6. Reassemble thrust spring, adjuster screw and lock-
nut on gear assembly. Torque locknut to 43
Ib.ft.7. Screw ball stud of the axial joint together with stop
plate onto both ends of the rack. Torque to 47
lb.ft.Counterhold rack with open-end wrench.
8. Slide rubber bellows onto axial joint and steering
gear housing. Attach rubber bellows with loose
clamp and clamping wire. Check that rubber bellows
is not twisted.
FlexibleCouplingClamp(GT)
Flexible Coupling Clamp (1 900
- Manta) _....,,,,,,....._...,,,,Tie
RodBall-Connects toRack (GT). . . . . .
BallStud - Axial Joint toRack (1900 - Manta)
Tie
RodLockNut(1900-Manta). . . . . .
Steering Gear Housing to Front Suspension
Crossmember (GT)
,,....._.._.................................................Steering Gear Housing to Front Suspension
Crossmember (1 900
- Manta) _...........................,...........Adjusting Screw Lock Nut.
.._.._....................................Pinion
. . . .._............_.......,,,,,.........................................,,,,..........,,Tie Rod to Steering Arm. .
.._.....................................
Torque
Lb.Ft..-
;“2
43
4749
18
29
43
:i

3D- 341973 OPEL SERVICE MANUALILOCK PLATE
7, @-, FLEXIBLE COUPLING NUTFLEXIBLE
COUPLING
-/BOLTPINION SHAFI
RUBBER BOOT
es+--RETAINER
ew O-RING
‘lNTERED METAL BUSHING 1y STEERING GEAR HOUSING @+ NEEDLE
BEARlNG
y-7RACK GUIDE BUSHING
RACK
he---THRUST SPRINGiRUBBERADJUSTER SCREW
BUSHING
ILOCK NUT
BOLT
\Figure 3D-17 Steering Gear Assembly Exploded View30-17

OPEL 1900 AND MANTA STEERING COLUMN ASSEMBLY3E- 37
Figure 3E-5 Steering Column Assembly With Gear
replacement of steering column or steering ignition
lock parts.
Removal (Opel 1900 . Manta)1. Disconnect battery.
2. From underside of car, remove clamp screw of
upper steering mast out of universal joint flange. See
Figure
3E-6.Figure
3E-6 Upper Steering Mast Clamp Screw
3. Remove hex nut from steering mast jacket attach-
ment at front of dash panel. See Figure
3E-7.Figure
3E-7 - Steering Mast Jacket Attachment
4. Pull off signal switch, as well as steering and igni-
tion lock wire sets.
5. Unscrew slide-off base from underside of instru-
ment panel and remove steering column assembly
from car. See Figure
3E-8. Carefully put down as-
sembly. Avoid impacts and blows to steering column
assembly.
Figure
3E-8 - Slide-Off Base Attaching Nuts
Installation (Opel 1900. Manta)
CAUTION:
Fasteners are important attaching parts in
that they could affect the performance of
vital com-

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.

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