1973 OPEL 1900 manual transmission

7A- 41973 dPEL SERVICE MANUALConditionPossible CauseCorrectionHeat-blued driven plate
and pressure plate
assembly.
1. Improper pedal1. Replace only driven plate, and
adjustment.adjust clutch pedal and cable.
Grab and chatter with
oil present on clutch
assembly.1. Oil leak.1. Correct oil leakage, clean
pressure plate in solvent, replace
driven plate and adjust pedal lash.
MAINTENANCE AND ADJUSTMENTS
CLUTCH LASH ADJUSTMENT
GTPedal lash, free pedal travel must be adjusted occa-
sionally to compensate for normal wear of the clutch
facings. As the driven plate wears thinner, pedal lash
decreases. Adjust clutch pedal free travel only with
ball stud located on right side of clutch housing if
cable length is not to be changed. To adjust pedal
lash proceed as follows:
1. Loosen lock nut on ball stud end located to the
right of the transmission on the clutch housing. Posi-
tion ball stud so that the outer end protrudes 3/4
inches out of housing and finger tighten lock nut. See
Figures
7A-1 and 7A-6.
2. Adjust ball stud, pivoting clutch release fork, to
obtain 3/4 to
l-1/4 inches pedal lash, free pedal. See
Figure 7A-6.
Opel 1900 and MantaThe clutch actuation works without clutch pedal free
travel. A readjustment of the clutch is only required
if the indicator lamp at the instrument panel lights
up.In synchronism with the gradual wear of the clutch
linings the clutch pedal travels from its basic adjust-
ment position upwards,
ie., towards driver. If the
clutch lining wear has reached such an extent that
the clutch pedal rests against switch, the indicator
lamp at the instrument panel lights up.
This is an indication that the clutch pedal position
has to be corrected to ensure proper clutch operat-
ion.
To
&~sure proper clutch operation, observe the fol-
lowing adjustment instructions.. For all adjustment
dimensions, refer to Figure 7A-7.
1. If the parking brake is provided with an indicator
lamp, the parking brake has to be disengaged, other-wise the same indicator lamp as for the clutch lights
UP.2. Carry out adjustment only with ball stud on clutch
housing whereby the distance (Item 20, Figure 7A-7)
between clutch housing contacting surface and
clutch release lever has to be adjusted in the rear to
4
l/4 inches.
Clutch Control Cable Adjustment(Only on
Installation of a New Clutch Disc or
Bowden
Control Wire)
GT1. Adjust ball stud so that outer end protrudes ap-
proximately 3/4 inches out of clutch housing.
2. Adjust distance between release lever and clutch
housing face at eye for control cable to approxi-
mately 4
l/4 inches. See Figure 7A-6. Hold cable in
this position and place E-ring two grooves ahead of
washer on rubber grommet. Clutch pedal free travel
is now between 3/4 and 1
l/4 inches and clutch
release bearing has proper clearance from pressure
plate.
Opel 1900 and Manta1. Adjust ball stud on clutch housing to basic dimen-
sion of approximately 3/4 inch. With lower end ofbowden control wire unhooked, push clutch release
lever towards the front so that the clutch release
bearing rests against clutch spring. Now, adjust ball
stud so that the dimension (Item 20, Figure
7A-7)between clutch housing contacting surface and
clutch release lever amounts in the rear to 4
l/4
inches.2. Pull reattached bowden control wire out of dash
panel so that clutch pedal rests against switch (in-
dicator lamp lights up).
3. In this position, install lockwasher at upper con-
trol wire attachment three grooves towards the front,
thereby completing control wire adjustment.

CLUTCH?A- 5MAJOR REPAIR
CLUTCH REMOVAL AND INSTALLATION
Remove Clutch1. Remove transmission. Refer to Manual Transmis-
sion for removal procedure.
2. Remove bolts from engine support brackets, both
sides. Let brackets hang by front bolts.
3. Remove flywheel cover pan.
4. Remove flywheel housing to engine attaching
bolts and pry housing from locating pins. See Figure7A-1.
/1. UPPER ATTACHING BOLTS
2. FLYWHEEL HOUSING
3. VENT HOLES
4. CLUTCH RELEASE LEVER BALL
STUD AND LOCK NUT
5. RECESS IN FLYWHEEL
HOUSING
6. CLUTCH RELEASE BEARING
SLEEVE
7. CLUTCH RELEASE LEVER
AND BOOT
7A-1Figure 7A-15. To remove release bearing from clutch fork, slide
lever off ball stud against spring action. Remove ball
stud lock nut and remove stud from housing. See
Figure
7A-2.
1. FLYWHEEL HOUSING
2. CLUTCH RELEASE LEVER
3. RELEASE LEVER BOOT
4. RELEASE BEARING SLEEVES. CLUTCH RELEASE BEARINGi-A-2
Figure 7A-2
6. If assembly marks on clutch assembly and fly-
wheel have become indistinct, renew with paint or
centerpunch.
7. Loosen clutch cover to flywheel attaching bolts
one turn at a time to avoid bending of clutch cover
flange until spring pressure is released.
8. Support the pressure plate and cover assembly
while removing last bolt, then remove pressure plate
and clutch driven plate assemblies. Clutch cover,
spring, and pressure plate must not be disassembled.
If necessary, replace complete assembly.
Inspection of ClutchWash all metal parts of clutch, except release bearing
and driven plate, in suitable cleaning solution to
remove dirt and grease. Soaking release bearing in
cleaning solution would permit solution to seep into
bearing and destroy the lubricant. Soaking driven
plate in cleaning solution would damage the facings.

7A- 61973 OPEL SERVICE MANUAL1. FIywheeI and Pressure PlateExamine friction surfaces of flywheel and pressure
plate for scoring or roughness. Slight roughness may
be smoothed with fine emery cloth, but if surface is
deeply scored or grooved the part should be re-
placed.
2.
CJutch Driven Plate
Inspect driven plate for condition of facings, loose
rivets, broken or very loose torsional springs.
If facings are worn down near rivets or are oily, the
plate assembly should be replaced. A very slight
amount of oil on clutch facings will cause clutch grab
and chatter. A large amount of oil on facings will
cause slippage. Removal of oil by solvents or by buff-
ing is not practical since oil will continue to bleed
from facing material when hot.
When oil is found on driven plate facings, examine
transmission drainback hole, pilot bushing, engine
rear main bearing and other points of possible oil
leakage.
Test the fit of driven plate hub on transmission main
drive gear for an easy sliding fit.
Regardless of whether the old plate or a new one is
to be installed, the plate should be checked for run-
out. Lateral run-out measured at disc circumference
should not exceed
.016 inch.
Inspect clutch release bearing for scoring or exces-
sive wear on front contact face. Test for roughness of
balls and races by pressing and turning front race
slowly. Inspect main drive gear pilot bushing in
crankshaft. If bushing is rough or worn it should be
Figure JA-3replaced. If replacement is necessary, remove bear-
ing with Tool J-21718 and Slide Hammer J-7004-1.
Install new bearing using J-21706. See Figure 7A-3
for removal procedure and Figure 7A-4 for installa-
tion.
\,,
Figure JA-4
Installation of Clutch1. Index alignment marks on clutch assembly and
flywheel. Place driven plate on pressure plate with
long end of splined hub facing forward toward the
flywheel. See Figure 7A-5.
2. Insert alignment Tool J-22934 through clutch
cover and driven plate.
3. Hold complete assembly against flywheel while
inserting end of Tool J-22934 into pilot bearing in
crankshaft.
4. Index the alignment marks and install four (4)
clutch cover to flywheel bolts finger tight. Complete
torquing bolts alternately and evenly one at a time.
5. Torque attaching bolts to 36 lb.ft. and remove
alignment tool.
6. Install release bearing.
7. Install flywheel housing and torque lower bolts to
36
lb.ft.8. Install flywheel housing lower cover.
9. Install clutch return spring and control cable.
10. Install transmission. See Manual Transmission
Section for procedure.
11. Adjust clutch control cable. Refer to paragraph7A-3.

7B- 121973 OPEL SERVICE MANUAL
MANUAL TRANSMISSION
CONTENTS
Subject
DESCRIPTION AND OPERATION:
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Power
Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DIAGNOSIS: (Not Applicable)
MAINTENANCE AND ADJUSTMENTS:
Adjusting
ReverseGearshiftBlocker. . . . . . . . . . . . . . . . . . . . . . . . . .Shift Lever Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ServicingGearshift
Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .MAJOR REPAIR:
Transmission
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installation
ofTransmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing and Installing
Speed0 Driven Gear
(Transmission
Removed). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ReplacingBushinginSelectorLever. . . . . . . . . . . . . . . . . . . . . . . . . .Transmission
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Transmission
Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPECIFICATIONS:
Specifications ..,....._....,......,.....,......,.,.....,,.,..,......,.,....,........
Page No.
78-12
7B-13
78-1978-l
9
7B-19
78-22
78-22
78-23
78-23
78-23
78-28
78-33

MANUAL TRANSMISSION78.13POWER FLOWIST
& 2ND GEAR
SLIDING GEARr2yDmSPEEDGEAR
1ST SPEED
GEAR ‘EREVERSE
-IDLER GEAR
COUNTERSHAFT GEAR
+/UNIT
- IST SPEED GEAR~LCOUNTERSHAFT GEAR UNITCOUNTERSHAFT GEAR UNIT
f-t3RD SPEED GEAR
REVERSE SPEED GEARCOUNTERSHAFT GEAR
UNIT - 2ND SPEED GEAR
POWER FLOW. NEUTRAL POSITION
Figure 78.1
Neutral PositionDRIVE(INPUT1
ERSHAFT
R UNIT
‘E GEAR
78-lThe countershaft gear unit and the mainshaft lst,
Znd, and 3rd speed gears are all idling in “Neutral”
position. The reverse idler gear is not engaged or in
mesh with any gear and, therefore, it is idle.

7B- 141973 OPEL SERVICE MANUAL
POWER FLOW - 1st SPEED
MAIN DRIVE GEAR (INPUT)
COUNTERSHAFT GEAR UNIT 1st SPEED GEAR
1 st SPEED GEAR
1st AND 2nd GEAR SLIDING GEAR1st AND 2nd SPEED SLIDING GEAR GUIDE UNITCOUNTERSHAFT GEAR
UI‘!IT DRIVE GEAR1st SPEED GEAR1st AND 2nd GEAR SLIDING GEAR
,st AND 2nd SPEED SLIDING GEAR GUIDE UN1MAINSHAFT (OUTPUT)
70-2Figure 78.2
First SpeedAfter synchronizing the speeds of the mainshaft and
the 1st speed gear, the 1st and 2nd gear sliding gear
shifts to the rear of the transmission and locks the 1st
speed gear to the mainshaft through the 1st and 2nd
speed sliding gear guide unit. This 1st and 2nd speed
sliding gear guide unit is internally splined to the 1st
and 2nd gear sliding gear and is
exl~ernally splined to
the mainshaft. Both the 3rd speed gear and the 2nd
speed gear are idling. The reverse idler gear is not
engaged with any gear and, therefore, it is idle.
With a 1st speed gear ratio of
3.428:1, the main drive
gear (input) must turn 3.428 revolutions for every
one revolution of the main shaft (output).
IT

MANUAL TRANSMISSION76.15POWER FLOW. 2nd SPEED
MAIN DRIVE GEAR (INPUT)
COUNTERSHAFT GEAR UNIT 2nd SPEED GEAR
2nd SPEED GEAR
1st AND 2nd GEAR SLIDING GEAR
1st AND 2nd SPEED SLIDING GEAR GUIDE UNITCOUNTERSHAFT GEAR UNIT DRIVE GEAR
2nd SPEED GEAR
1st AND 2nd GEAR SLIDING GEAR
Ist AND 2nd SPEED SLIDING GEAR GUIDE UIMAINSHAFT (OUTPUT)
76Figure 78.3
Second SpeedAfter synchronizing the speeds of the mainshaft and
the 2nd speed gear, the 1st and 2nd gear sliding gear
shifts toward the front of the transmission and locks
the 2nd speed gear to the mainshaft through the 1st
and 2nd speed sliding gear guide unit. This 1st and
2nd speed sliding gear guide unit is internally splined
to the 1st and 2nd gear sliding gear and is externally
splined to the mainshaft. Both the 3rd speed gear and
the 1st speed gear are idling. The reverse idler gear
is not engaged with any gear and, therefore, it is
idle.
With a 2nd speed gear ratio of
2.156:1, the main
drive gear (input) must turn 2.156 revolutions for
every one revolution of the mainshaft (output).
VIT
i-3

78. 161973 OPEL SERVICE MANUAL
POWER FLOW
- 3rd SPEED
MAIN DRIVE GEAR (INPUT)
COUNTERSHAFT GEAR UNIT 3rd SPEED GEAR
3rd SPEED GEAR
GEAR SHIFTER SLEEVE
GEAR SHIFTER SLEEVE CARRIERCOUNTERSHAFT GEAR UNIT GEAR DRIVE
3rd SPEED GEAR
GEAR SHIFTER SLEEVE
GEAR SHIFTER SLEEVE CARRIER
MAIN SHAFT (OUTPUT)
78-4
Figure 78.4
Third Speed
After synchronizing the speeds of the mainshaft and
the 3rd speed gear, the gear shifter sleeve shifts to the
rear of the transmission and locks the 3rd speed gear
to the mainshaft through the gear shifter sleeve car-
rier. This gear shifter sleeve carrier is internally
splined to the gear shifter sleeve and is externally
splined to the mainshaft. Both the 1st speed gear and
the 2nd speed gear are idling. The reverse idler gear
is
not engaged with any gear and, therefore, it is
idle.
With a 3rd speed gear ratio of
1.366:1, the main drive
gear (input) must turn 1.366 revolutions for every
one revolution of the mainshaft (output).