1973 OPEL 1900 manual transmission

MANUAL TRANSMISSION78.17POWER FLOW
- 4th SPEED
MAIN DRIVE GEAR (INPUT)
GEAR SHIFTER SLEEVE
GEAR SHIFTER SLEEVE CARRIERGEAR SHIFTER SLEEVE
GEAR SHIFTER SLEEVE CARRIER
MAIN SHAFT (OUTPUT)7E5
Figure 78.5
Fourth SpeedAfter synchronizing speeds of the main drive gear
and mainshaft, the gear shifter sleeve shifts forward
and locks the main drive gear to the mainshaft
through the gear shifter sleeve carrier. This carrier is
internally splined to the gear shifter sleeve and is
externally splined to the mainshaft. The 3rd speed
gear, 2nd speed gear, and the 1st speed gear are all
idling. The
reverse idler gear is not engaged with
any gear and, therefore, it is idle.
With a 4th speed gear ratio of 1.000: 1, the main drive
gear (input) must turn 1.000 revolutions for every
one revolution of the mainshaft (output).

MANUAL TRANSMISSION76.19
DIAGNOSIS
MANUAL TRANSMISSION DIAGNOSIS
ConditionPossible CauseNoisy in Forward Speeds1) Low lubricant level.
2) Incorrect lubricant.
3) Transmission misaligned or loose.
4) Front main bearing worn or damaged.
5) Mainshaft bearing worn or damaged.
6) Countergear or bearings worn or damaged,
7) Main drive gear worn or damaged.
8) Synchronizers worn or damaged.
Noisy in “Reverse”1) Reverse sliding gear or shaft, worn or damaged
Hard Shifting1) Clutch improperly adjusted.
2) Shift shafts, or forks worn.
3) Incorrect lubricant.
4) Synchronizers worn or broken.
Jumping Out of Gear1) Partial engagement of gear.
2) Transmission misaligned or loose.
3) Worn pilot bearing.
4) End play in main drive gear (bearing retainer
loose or broken, loose or worn bearings on
main drive gear and mainshaft).
5) Worn clutch teeth on main drive gear and/or
worn clutch teeth on synchronizer sleeve.
6) Worn or broken blocking rings.
7) Bent mainshaft.
Sticking in Gear1) Clutch not releasing fully.
2) Low lubricant level.
3) Incorrect lubrication.
4) Defective (tight) main drive gear pilot
bearing.
5) Frozen blocking ring on main drive gear cone.
6) Burred or battered teeth on synchronizer
sleeve and/or main drive gear.
MAINTENANCE AND ADJUSTMENTS
ADJUSTING REVERSE GEARSHIFT BLOCKER1. Engage second speed.
2. Adjust selector ring (a) so that ball on lower end
of shift finger has an equal clearance on both sides
when seated into the transmission case extension bolt
hole. See Figure
7B-7.3. Back off selector ring an additional
l/4 of a turn
and tighten lock nut (B). See Figure
7B-7.SERVICING GEARSHIFT LEVER
Removal1. Unscrew console from floor panel, on small con-
sole remove three (3) attaching screws, on large con-
sole remove four (4) attaching screws. The fourth
screw is accessible after removal of the ash tray. See
Figure
7B-8.2. Remove rubber bellows from cover plate and from
below unbutton protective cap arranged around in-
termediate shift lever.

MANUAL TRANSMISSION78.2178-12
Figure 78-l 2
Figure
78.132. Knock off gearshift lever button and loosen
threaded pin for Bowden control wire attachment.
See Figure 7B-12.
3. Drive spiral pin and clamping sleeve out of shift
finger tube and stop sleeve. See Figure 7B-14.
4. Remove shift finger and pull Bowden control wire,
together with thrust spring, out of gearshift lever.
5. Oil sliding surface of stop sleeve on shift finger
tube with clutch oil.
6. After installation of thrust spring, attach newBowden control wire first with clamping sleeve.
When doing this, the cutout of stop sleeve in installa-
tion position shows to the left. The spiral pins must
not protrude on either side.
7. Clamp tight Bowden control wire with threaded
pin. Prior to tightening, pull ring must rest on gear-
shift lever tube and clamping block on pull ring.SPIRAL PINS7B-14
Figure 71-14
8. Heat up new gearshift lever knob in boiling water
to 176 degrees F. and push it onto lever tube. Ob-
serve distance A
- .3”, see Figure 7B-15. The gear-
shift lever tube end is provided with transverse
grooves for which reason the old button can no
longer be used.7515
Figure
78-l 5
9. Attach shift finger with spiral pin and install gear-
shift lever.
REPLACING GEARSHIFT LEVER BELLOWS
1. Remove gearshift lever.
2. Knock off gearshift lever button and pull off bel-
lows over pull ring.

78.221973 OPEL SERVICE MANUAL
3. Install new bellows. Adhere to distance A
- 8.07”.
See Figure 7B-I 1.
4. Heat up new gearshift lever knob in boiling water
to 176 degrees F. and push it onto gearshift lever
tube. Adhere to distance A .3”, see Figure
7B-15.The gearshift lever tube end is provided with trans-
verse grooves for which reason the old button cannot
be reused. Install gearshift lever.
REPLACING RUBBER DAMPENING PARTS IN
GEARSHIFT LEVER1. Remove gearshift lever.
2. Knock off gearshift lever button and loosen
threaded pin for Bowden control wire attachment.
3. Remove lower snap ring from gearshift lever tube
and pull tube off shift finger.
4. Take off and replace rubber dampening parts.
5. After installation of tube, tighten Bowden control
wire with threaded pin. Prior to tightening, pull ring
must rest on gearshift lever tube and clamping block
on pull ring. See Figure
7B-15.6. Heat up new gearshift lever knob in boiling water
to 176 degrees F. and push it onto gearshift lever
tube. Adhere to distance A
- .3”, see Figure 7B-15.The gearshift lever tube end is provided with trans-
verse grooves for which reason the old button cannot
be reused.
7. Install gearshift lever.
MAJOR REPAIR
TRANSMISSION REMOVAL1. Remove air cleaner. Remove throttle rod from
carburetor and rear support and disconnect battery.
2. Remove screws from fan shroud.
3. Remove gearshift lever (refer to paragraph on ser-
vicing gearshift lever).
4. Support car with frame or wheel stands in the
front or frame stands in the rear.
5. Loosen front exhaust pipe to manifold flange.
6. Remove clutch cable from fork by pushing fork to
disengage the clutch and unsnap cable from slot.
7. Disconnect both wires from backup lamp switch.8. Disconnect speedometer cable from transmission
case extension housing.
9. Unhook parking brake cable return spring and
remove cable adjusting nut, equalizer, and spacer.
See Figure
7B-16.PARKING BRAKE CABLE
PARKING BRAKE
Figure 78-16 Parking Brake Equalizer and Return
Spring
9. Disconnect drive shaft at central joint and remove
as follows: See Figure
7B-16.a. Disconnect parking brake cable equalizer from
rod.b. Mark the mating parts of U-Joint and the drive
pinion extension shaft flange.
c. Loosen bolt locks and remove bolts or nuts.
d. Work propeller shaft slightly forward, lower rear
end of shaft and slide assembly rearward. Remove
thrust spring.
e. Install a plug in the rear of the transmission to
prevent loss of lubricant.
10. Remove rear engine mount bolts and lower trans-
mission as far as possible.
11. Remove transmission case to clutch housing at-
taching bolts and remove transmission.
INSTALLATION OF TRANSMISSION WITH
ENGINE IN CAR1. Make certain main drive gear splines are clean and
dry. Also, make certain the transmission is in Neu-
tral so that the main drive gear splines may be in-
dexed when making the installation.
2. Install transmission and support weight while in-
stalling transmission case to clutch housing bolts.
3. Install rear engine mount.
4. Install propeller shaft, align, and tighten U-Joint
to pinion flange U-Bolt nuts and torque to 11 lb. ft.

MANUAL TRANSMISSION70.235. Attach clutch cable.
6. Perform clutch lash adjustment. See Clutch, Sec-
tions A and B for adjustment procedure.
7. After overhaul of transmission, refill with
2- l/2pints of SAE 80 or SO-90 multi-purpose gear Iubri-
cant.
REMOVING AND INSTALLING SPEED0 DRIVEN
GEAR
(WITH TRANSMISSION REMOVED)
Removing Speedo Driven Gear Assembly1. Use wrench to unscrew speed0 angular drive hold-
ing nut and remove speedo angular drive.
2. With Special Tool J-22926 and Slide Hammer
J-7004- 1, remove speedo driven gear lock pin which
retains speed0 driven gear assembly in transmission
case extension housing.
3. Using Special Tool J-22929 and Slide Hammer
J-7004- 1, remove speed0 driven gear assembly. Tool
J-2292? screws onto the speedo driven gear guide
making it possible to remove the guide and assembly
without damage to the transmission case extension
housing.
Installation of Speedo Driven Gear Assembly1. Using Special Tool J-22929 install speedo driven
gear assembly into transmission case extension hous-
ing. It may be necessary to tap lightly on tool
J-22929 when installing assembly. Be sure speedo
driven gear lock pin hole on guide lines up with hole
in transmission case extension housing. Also, rotate
mainshaft at output end when inserting speed0
driven gear assembly to insure that driven gear
meshes properly with speed0 drive gear on main-
shaft.2. Install speed0 driven gear lock pin into transmis-
sion case extension housing by tapping pin lightly.
3. Install speed0 angular drive by tightening speedo
angular drive to holding nut.
REPLACING BUSHING IN SELECTOR LEVER
(TRANSMISSION AND GEARSHIFT LINKAGE
REMOVED)
Removal1. Remove snap ring from bushing. See Figure 7B-
17.2. Using a suitable brass drift drive out bushing from
snap ring side. See Figure
7B-19.SNAP RING
Figure 78.17 Snap Ring on Selector Intermediate
Lever Bushing
Figure 78.19 Removing Bushing From SelectorIntermediate Lever
Installation1. Using a suitable tool drive in bushing up to stop.
Install bushing in opposite direction of removal with
the cutout in the bushing facing upwards. See Figure7B-
19.2. Install snap ring onto bushing.
TRANSMISSION DISASSEMBLYMaintain the respective positions of all mating parts
during overhaul.

78.241973 OPEL SERVICE MANUAL
Removing Shifter Shaft
1. Remove cotter pins that secure each end of shifter
shaft. See Figure
7B-20.7&20
Figure 78.20 Cotter Pin Locations on Shifter Shaft
2. Remove shifter shaft with washer and spring
washer at each end.
Removing Selector Lever
1. With punch, drive out pin securing selector lever
to transmission case extension bolt. See Figure 7B-
21.
Figure
78-21 Pin and Bracket Securing Selector
Lever to Intermediate Shaft and Rear Bearing
Retainer2. Remove the two (2) bolts and spring washers from
the transmission case extension housing which se-
cure selector lever bracket. See Figure 7B-2 1.
3. Remove selector lever and bracket. Selector lever
will just slip off selector ring.
4. Remove lock nut and selector ring.
5. Remove transmission case extension bolt. See Fig-
ure 7B-21.Removing Transmission Case Cover
1. Remove ten (10) transmission case cover bolts,
cover, and gasket.
2. Invert transmission to drain oil.
Removing Countergear
1. Remove remaining three transmission case exten-
sion housing to case attaching bolts and spring wash-
ers.2. Turn transmission case extension housing until
gear unit countershaft is exposed. See Figure 7B-22.
Figure
78-22 Position of Rear Bearing So
Countergear Can Be Removed
3. From the front of the transmission, using Special
Tool J-2291 1, drive out shaft. Ensure that lock ball
is not lost. See Figure 7B-23.
Figure
78-23 Removing Countergear Shaft

MANUAL TRANSMISSION78.254. With Special Tool J-2291 1 inserted, take counter-
shaft gear unit out of transmission case. Remove
both thrust washers.
Removing Selector Shaft and Intermediate Levers
1. Drive out reverse intermediate lever bedding bolt
and remove reverie speed shifter intermediate lever.
See Figure 7B-24.*EVE&E
JNTERME!Figure
78-24 Driving Out Reverse Intermediate LeverPin2. To remove all pins, use a
l/8 inch pin punch. Turn
the selector shaft so that lock pins are in vertical
position. First, drive lock pins out of third and fourth
speed intermediate lever and then out of first and
second speed intermediate lever. See Figure 7B-25.3. Push selector shaft out of case and remove inter-
mediate levers.
4. With screwdriver, pry out selector shaft oil seals
on transmission case.
Removing First and Second Gear Shifter Shaft,
Yoke, and Cam1. Pull out both lock ball plugs using Tool J- 21715
with Slide Hammer J-7004-1. Remove thrust
springs.
2. With transmission in first gear, drive lock pins out
of shifter yokes and shifter shaft cam. See Figure7B-26.
Figure
78-26 Position of Lock Pins for Shifter Forks
and Selector Dogs
3. Turn extension housing until shifter shaft is ex-
posed. From the rear of transmission, drive out first
and second speed shifter shaft. Use suitable brass
drift. See Figure 7B-27.
Figure
78-25 Removing Lock Pins from Selector Shaft
Figure 78.27 Removing Shifter Shafts

78.261973 OPEL SERVICE MANUAL
4. Remove both first and second speed shifter yoke
and shifter shaft cam.
Removing Main Drive Gear and Mainshaft
Assembly
1. From front of transmission, pull main drive gear
and needle bearing out of transmission. (May be
necessary to rock main drive gear.)
2. From rear of transmission, pull mainshaft assem-
bly and transmission case extension housing out of
transmission. Gear shifter sleeve will be pulled off
gear shifter sleeve carrier by the third and fourth
speed shifter yoke. Remove sleeve from yoke and
keep sleeve with mainshaft assembly. (Make sure
third and fourth speed shoes are not lost.)
Removing Third and Fourth Gear Shifter Shaft.
1. With main shaft assembly out of transmission
case, drive third and fourth gear shifter shaft out
through hole in front of case with brass drift from
rear of transmission through mainshaft assembly
hole in case.
2. Remove third and fourth speed yoke.
Removing Reverse Gear Shifter Shaft and Reverse
Idler Gear
1. Using a brass drift and from the front of the trans-
mission, drive out reverse gear shifter shaft and plug.
See Figure
7B-28. The reverse speed shifter yoke will
remain in transmission case.
Figure 78.28 Removing Reverse Shifter Shaft
2. With Special Tool J-22923 push reverse idler gear
shaft from front toward the rear. Ensure that lock
ball is not lost. See Figure
7B-29.Figure 78.29 Removing Reverse Idler Gear Shaft
3. Take shaft, reverse idler gear and reverse speed
shifter yoke out of transmission case.
Disassembling Mainshaft Assembly
1. Remove mainshaft bearing snap ring from trans-
mission case extension housing groove and remove
mainshaft assembly from housing. See Figure
7B-30.Figure 78-30 Removing Snap Ring From Rear Bearing
Retainer2. Remove loose parts such as mainshaft needle bear-
ing, mainshaft front ring, synchronizer cover, gear
shifter sleeve, shoes, and front synchronizer spring.
The gear shifter sleeve carrier and the first and sec-
ond speed sliding gear guide unit and their respective
gear shifter sleeve and first and second gear sliding
gear are selected assemblies and should be kept
together as originally assembled. See Figure 7B- 31.