1973 OPEL 1900 manual transmission

MANUAL TRANSMISSION78-27
SYNCHRONIZER
SPAZER RINGf&31Figure 78.31
3. Remow snap ring from in front of clutch hub. See
Figure
7B-32.
SPEED
DRIVEFigure 78.33 Removing Snap Ring Behind
Speedometer Drive Gear
CLUTCH HUBFigure
7%.32 Removing Snap Ring In Front of ClutchHub4. Using Tru-arc pliers, remove snap ring behind
speedometer drive gear. See Figure
7B-33. Removespeedo drive gear spring washer and speed0 drive
worm gear.
5. Remove drive gear lock ball from mainshaft. See
Figure
7B-34.6. Press mainshaft inner bearing from mainshaft us-
ing Special Tool J-21684, Press Plate, as shown in
Figure 7B-35 and then, by hand, remove all loose
parts such as mainshaft washer, transmission case
extension housing snap ring, first speed gear, first
speed needle bearing, synchonrizer cover, first and
second gear sliding gear, shoes, and rear synchro-
nizer spring, See Figure
7B.370DRIVE GEAR
LOCK BALL
Figure 78.34
Speedo Drive Gear I.ock Ball on Mainshaft
l-21 684
BALL
BEARING
/
Figure 78.36 Removing Rest Bearing Frotii Mainshaft

iB- 281973 OPEL SERVICE MANUAL
1 ST SPEED
GINEEDLE BEARING-/CLUTCH
SLEEc?iE,-.
SNAP RING_.. ..~~ ~-KEY SPRING,a-37Figure 70-37Figure 7B-39 Pressing Off Small Clutch Hub
7. With Special Tool J-21684, Press Plate, located
below third speed gear, press out gear shifter sleeve
carrier. See Figure
7B-38.2. Install third speed synchronizer cover onto third
speed gear cone.
J-21604
\
2ND SPEED
GE,ARFigure 78.38 Pressing Off Large Clutch Hub and
Needle Bearing Inner Sleeve8. With Special Tool J-21684, Press Plate, located
below second speed gear, press out gear shifter sleevecarrier. See Figure
7B-39.
TRANSMISSION REASSEMBLY
A. Assembling Mainshaft1. From front of the mainshaft install third speedf;cz&mto mainshaft. Gear must turn freely on main-3. Install rear synchronizer spring into rear side of
gear shifter sleeve carrier so that hooked spring end
rests in one of the slots.
4. Using Press Plate J-21684, press gear shifter sleeve
carrier onto mainshaft so that original tooth contact
is obtained. The rear side of gear shifter sleeve carrier
with installed spring should be toward third speed
gear. This rear side of carrier is recessed more than
front side to allow carrier to be pressed almost flush
with synchronizer cover. See Figure
7B-40.3rd
8 4th
Figure 78.40 Securing Third and Fourth Speed Clutch
Hub on Mainshaft With Snap Ring

MANUAL TRANSMISSION78.29
5. Using external snap ring pliers, secure gear shifter
sleeve carrier on mainshaft with snap ring. See Fig-
ure
7B-40.6. From rear of mainshaft, slide second speed gear
onto mainshaft. Gear must turn freely on mainshaft.
See Figure
7B-41.
2ND SPEED
GEAR CONE\
3RD SPEED
GEAR
MAIN
L; SYNCHRONIZER
VER2ND SPEED
GEAR
7B.41Figure
7B-41 Second Speed Gear and Synchronizer
Ring Installed
7. Place second speed synchronizer cover onto sec-
ond speed gear cone. See Figure
7B-41.
8. Install both synchronizer springs into first and
second speed sliding gear guide unit so that hooks of
both springs rest in the same guide unit shoe slot and
the other spring ends are positioned opposite to each
other. See Figure 78-42.
9. Press first and second speed sliding gear guide unit
onto mainshaft so that the original tooth contact is
obtained.
10. Using Tool J-22913, press first speed gear needle
bearing inner sleeve onto mainshaft.
11. Using Tool J-22913, install tirst and second speed
shoes (long style) and install first and second gear
sliding gear (forked groove to rear) onto first and
second speed sliding gear guide unit.
12. Slide first speed gear needle bearing, synchro-
nizer cover, first speed gear, mainshaft washer
(chamfer toward rear), and mainshaft bearing snap
ring onto mainshaft.
13. Press on mainshaft inner bearing using Tool
J-22913. See Figure
7B-43.GUIDE UNIT
SYNCHRONWER SPRING
Figure 78.42 Both Clutch Key Springs Installed
RI
d-J-22913 MAINSHAFT
ASSEMBLY TOOL
---- .
~.
7B.uFigure 78.43 Pressing on Rear Bearing Using Tool
J-22913
14. Insert lock ball in place in mainshaft and place
speedo drive worm gear and speed0 drive gear spring
washer on mainshaft. Secure with speedo drive gear
snap ring.
15. Place mainshaft assembly into transmission case
extension housing up to its stop. Secure with main-
shaft bearing snap ring. See Figure 7%44.

78.301973 OPEL SERVICE MANUAL
SHOULDER OR
SHIFTE
.44Figure 78-46 Installing Reverse Shifter Fork
Figure 78.44 Mainshaft Assembly Secured Into Rear
Bearing Retainer by Snap Ring
16. Place front synchronizer spring in the gear shifter
sleeve carrier. Install (3) third and fourth speed shoes
(short design) and gear shifter sleeve over gear shifter
sleeve carrier along with synchronizer cover. Arrows
on shoes point toward rear of mainshaft. Gear shifter
sleeve yoke groove should be toward front.
17. With sealer, install new gasket onto transmission
case extension housing.
Installing Reverse Idler Gear and Reverse Gear
Shifter Shaft1. Inspect shafts carefully for burrs, and remove with
emery cloth. Burrs on shifter shaft will prevent easy
installation of shifter yoke. Lightly oil with transmis-
sion oil prior to installation. Place lock ball into
reverse idler gear shaft and push shaft through hole
in rear of case and on through reverse idler gear
which should have groove end toward front. See Fig-
ure
7B-46.Continue to drive reverse idler gear shaft forward
with plastic hammer until rear end of shaft is flush
with rear case face.
2. Position reverse speed shifter yoke in groove of
reverse idler gear and install reverse gear shifter shaft
from rear of case with notches up, pushing it through
reverse speed shifter yoke. See Figure
7B-47.3. Install spiral pin to secure yoke to shifter shaft and
drive plug into hole in rear of case.Figure 78.47 Third and Fourth Speed Shifter Shaft
Installed
Installing Mainshaft Assembly and Main Drive
Gear1. Slide mainshaft assembly into transmission case
from rear.
2. From the’front, slide mainshaft front ring and the
mainshaft needle bearing onto the mainshaft. See
Figure
7B-48.3. Install main drive gear through front of transmis-
sion case until main drive (standard part) snap ring
is flush with case.
Installing Third and Fourth Gear Shifter Shaft1. Position third and fourth speed yoke onto gear
shifter sleeve. See Figure
7B-47.2. Insert third and fourth gear shifter shaft through
hole in front of case with notches down, pushing it
through third and fourth speed yoke. Third and

MANUAL TRANSMISSION70.31COUNTER SHAFT GEAR
THRUST WASHER\Figure 76.48 Installing Spacer Ring and Needle
Bearing Onto Mainshaft
fourth speed yoke should be positioned with rounded
notch at shaft hole portion of yoke toward rear. See
Figure 78. 47.
3. Install spiral pin, allowing
i/16” to 5/64” of pin
to protrude.
Installing First and Second Gear Shifter Shaft
1. Inspect shifter shaft carefully for burrs, and
remove with emery cloth. Burrs on shifter shaft will
prevent easy installation of shifter yoke and cam.
Lightly oil with transmission oil prior to installation.
Insert first and second gear shifter shaft through hole
in rear of case with three notches down and toward
rear of transmission, pushing shaft tirst through
firstand second gear shifter yoke, which should be posi-
tioned on first and second gear sliding gear with
shoulder toward front of case. To position first and
second gear shifter yoke on first and second gear
sliding gear, push reverse idler gear forward, engag-
ing the idler gear with the first and second gear
sliding gear. This will make room for positioningfirst and second gear shifter yoke. See Figure
7B-49.2. Continue to drive first and second gear shifter
shaft through shifter shaft cam, which should be
positioned as shown in Figure
7B-50.3. Install spiral pins to secure shifter yoke and shifter
shaft cam to first and second gear shifter shaft.
Installing Selector Shaft
1. Inspect selector shaft carefully for burrs, andFigure
78.49 Countergear Thrust Washers Installed
Figure
78-50 Position of “L” Shaped Selector Dog
remove with emery cloth. Burrs on shaft will prevent
easy installation of intermediate levers. Lightly oil
with transmission oil prior to installation. Insert new
selector shaft oil seals in holes on both sides of trans-
mission case and insert selector shaft into case and
through third, fourth, and reverse intermediate lever.
Third, fourth, and reverse intermediate lever should
be positioned on selector shaft, as shown in Figure
7B-51.2. Continue to push selector shaft through first and
second intermediate lever and through other side of
case. First and second intermediate lever should be
positioned on selector shaft, as shown in Figure 7B-
52. Selector shaft is rotated counterclockwise (when
looking from lever end of selector shaft) from work-
ing position to have spiral pin holes in shaft vertical
and in line with pin holes in intermediate levers. To
rotate selector shaft in this manner, the reverse gear
shifter shaft and its reverse speed shifter yoke must
be pushed rearward so that the reverse idler gear is
against rear of case.

Figure 78-5 1 Position of Third, Fourth, and Reverse
Intermediate Lever on Selector Shaft
1ST. 2ND IlrFigure 78.52 Position of First and Second
Intermediate Lever on Selector Shaft
3. Install spiral pins to secure both intermediate lev-
ers to the selector shaft. Spiral pins should not be
flush with lever surface, but rather should extend up
between
l/16 and 5/64 inches.
Installing Reverse Speed Shifter Intermediate
Lever and Interlock Balls, Springs, and Plugs
1. Engage reverse speed shifter intermediate lever
with third, fourth, and reverse intermediate lever and
also in slot in reverse gear shifter shaft, and install
79-321973 OPEL SERVICE MANUAL
bedding bolt through reverse speed shifter intermedi-
ate lever and into case. Reverse speed shifter inter-
mediate lever end play on bolt should be between
,004 and .012 inches.
2. Insert both interlock balls and then springs, and
drive both interlock plugs into case holes until they
bottom in interlock plug hole seats. Grooves in plugs
will be showing.
Installing Countershaft Gear Unit
1. Coat thrust washers with ball and roller bearing
grease and stick to transmission case. Lugs of thrust
washers must fit into transmission case slots. See
Figure
7B-49.2. Turn transmission case extension housing until
gear unit countershaft bore is completely exposed.
3. Place lock ball into shaft and from the rear of the
transmission insert shaft so that thrust washer is held
in position. Hold opposite thrust washer in position
by using a short drift.
4. Insert countershaft gear unit into transmission
case. Be sure all needle bearings and both needle
bearing washers are in place.
5. Insert gear unit countershaft into gear unit and
drive shaft into transmission case while driving out
Special Tool J-2291 1. Pay attention to lock ball. See
Figure
7B-53.Figure 78-53 Installing Countergear Shaft
Installing Transmission Case Extension Housing
1. Align transmission case extension housing and
gasket and torque (3) bolts with spring washers to 21
lb. ft.

MANUAL TRANSMISSION70-33
Installing Gearshift Interlock Ball and Gearshift
Thrust Spring1. Install gearshift interlock ball into top transmis-
sion bore and then install gearshift thrust spring.
Installing Transmission Case Cover1. Install case cover gasket, cover, and tighten
screws.
Installing Gearshift Linkages1. Install selector ring and lock nut onto selector
shaft.2. Holding selector lever and support in place, torque
(2) bracket bolts and spring washers to 14.5 lb. ft. See
Figure
7B-55.3. Install pin securing selector lever to transmission
case extension bolt.Figure 78.55 Pin and Bracket Securing Selector
Lever to Intermediate Shaft and Bearing Retainer
4. Install shifter shaft with spring washers on inside
of shifter shaft ends and flat washers on outside ofshaft.5. Secure each end of shifter shaft and washers with
new cotter pins.
SPECIFICATIONS
TRANSMISSION SPECIFICATIONS
General SpecificationsType
................................................................Manual Shift 4 Speeds Forward - 1 Reverse
Synchronization
........................................................FullySynchronizedAllForwardSpeedsGear Ratios:
1st Gear
........................................................................................................................3.4282nd Gear
........................................................................................................................2.1563rd Gear
........................................................................................................................1.3664th Gear
........................................................................................................................
1.000Reverse
..........................................................................................................................3.317Lubricant Capacity
........................................................................................................2.5 pints
Lubricant Type
............................................SAE 80 or SO-90 Multi-Purpose Gear Lubricant
Torquing Specifications
Part
BoltBolt
Bolt
Bolt
Location
TransmissiontoFlywheel
(3) Rear Bearing Retainer to Transmission Case
(M&25)(2) Rear Bearing Retainer to Transmission Case(MBr30)
RearEngineMounttoUnderbody
Torque
Lbs.Ft.32.36
21
14.5
22

79.341973 OPEL SERVICE MANUAL
1.9 Engine TransmissionFigure 78-57 Exploded View of Manual Transmission