1973 OPEL GT-R suspension

3A- 6 1973 OPEL SERVICE MANUAL
Figure 3A-10 Steering Mast Clamp Bolt
assembly at the cross member to body support from
frame and let it down onto jack. See Figure
3A-11.
Figure 3A-1 1
Installation
GT
CAUTION: Fasteners are important attachingparts in
that they could affect the performance of vitaI com-
ponents and systems, and/or
coo/d 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 or lesser quality or substitute design. Torque
values
must be used as speciiied during reas-
sembly to assure proper retention of these parts.
I. Support front suspension and cross member on
jack and raise into position.
2. Attach cross member to front frame rail. Torque
to 36
lb.ft.
3. Install engine mounting nut? Remove engine sup-
port.
4. Install shock absorber mounting bolts and install
air cleaner.
5. Connect brakes hoses and bleed brakes as outlined
in Group 5.
6. Install radiator mounting bolt in support cross
member.
7. Push steering column downwards until a
l/8”
clearance is obtained between steering wheel hub and
switch cover.
8. With steering wheel in centered position and front
wheels straight ahead, tighten the clamp bolt at the
lower universal joint to 22
fbs.fi. and the clamp at
the upper universal joint to 14
lbs.ft. See Figure
3A-6.
9. Inr;tall mast guide sleeve stop bolt. Always install
new lock plate. See Figure
3A-7.
10. Remove front support stands and lower vehicle.
Installation Opel 1900 - Manta
1. With jack, lift up front suspension assembly so
that the individual attaching points coincide. At the
same time, insert lower steering mast into pinion
flange. See Figure
3A-12.
2. In the rear bolt cross member to body support.
Torque to 58
ft.lbs. When doing this with a suitable
tool, counterhold damper bushing which is installed
in a certain position, to prevent it from turning. For
this purpose, detach heat
deflectqr plate on right
vehicle side.
3. Torque front suspension assembly to frame attach-
ment to 47
ft.lbs.
4. Torque lower steering mast to pinion flange at-
tachment clamp bolt to 22
ft.lbs.
5. Reinstall both brake calipers. Torque to 72 ft.lbs.
Install brake line retainer.
6. On both sides install upper control arm ball joint.
Torque bolts to 29
ft.lbs.

FRONT SUSPENSION3A- 7
Figure 3A-12 Front Suspension Attaching Points
Always use new self-locking nuts.
7. Reinstall guard plate.
8. Crosswise torque wheel nuts to 65 ft.lbs.UPPER BALL JOINT REMOVAL AND
INSTALLATION
RemovalI. Place jack under spring eye and raise car. Remove
wheel from car.
2. Remove cotter pin and castle nut from upper ball
joint stud. Discard cotter pin.
3. Press ball stud from steering knuckle using puller
J-21687, and remove two (2) bolts attaching ball
joint to upper control arm. See Figure 3A-13.
4. If dust cap on upper ball joint is torn or missing,
the ball joint should be replaced.
Installation
CAUTION:
Fasteners are important attachingparts in
that they could
afEct the pertkmance 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
equivaknt pa-t if
replacement becomes necessary. Do not use a re-
placement part of lesser quality or substitute design.
Torque values must be used as specified
durikg reas-
sembly to assure proper retention of these parts.Figure 3A-13 Upper Ball Joint
1. Install upper control arm ball joint with the off
center holes in flange showing towards the steering
knuckle spindle.
2. Install two (2) bolts attaching ball joint to upper
control arm. Torque nuts to 29 Ibft.
3. Install upper ball joint stud in%eering knuckle
and torque castle nut to 29
Ib.ft. on GT and 40 lb&.
on Opel
1900 - Manta.
4. Install new cotter pin, and replace wheel.
5. Always check caster and camber after installing
new ball joints.
LOWER BALL JOINT REMOVAL AND
INSTALLATIONNew lower ball joints have an axial play of up to
,020inch. The maximum permissible axial play of older
ball joints is
,080 inch. At an axial play of more than
,080 inch, the lower ball joint must be replaced. If the
dust cap is torn, loose, or missing, the lower ball joint
must also be replaced. See Figure
3A-14.The lower ball joints are checked for wear by using
Checking Gauge J-23402 for the GT, and using
Checking Gauge J-23745 for the Opel 1900
- Manta.
See Figure
3A-15.
Removal GT1. Raise car and support at rear of front frame rails.
2. Remove front wheel.

FRONT SUSPENSION3A- 9
8. Press ball stud out of lower control arm.Removal Opel 1900 - MantaBefore raising vehicle, install Hooks J-23697 on re-
spective vehicle side to cross member and upper con-
trol arm. See Figure 3A-7.
1. Raise car and support at rear of front frame rails.
2. Remove front wheel.
3. At the lower control arm ball joint, remove castle
nut cotter pin and slacken back nut so that the thread
can no longer be damaged.
4. With a suitable drift, detach ball joint from steer-
ing knuckle. With jack, lift up lower control arm,
unscrew castle nut and remove Hooks J-23697.
5. Unscrew upper control arm ball joint and suspend
front wheel hub and brake caliper in wheel house. Do
not turn upper control arm ball joint flange, as this
would result in a change of camber.
6. Remove defective lower control arm ball joint
using Tools J-9519 and Receiver J-23754.
Installation GT
CAUTION:
Fasteners are important attachingparts in
that they could affect the performance of
vitaI com-
ponents and systems, and/or could result in
ma&r
repair expense. They must be replaced with one of
the same part
numer 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. When pressing the ball joint in place, make certain
the locating notch in the lower rim of the ball joint
matches the alignment reference mark placed on the
lower control arm prior to removal. The notch in the
ball joint bottom plate, identifying the direction of
the elongated slot, must point towards the brake
drum backing plate. See Figure
3A-17. Alignment
must be within 2 degrees of lower control arm center-
line. If proper positioning of the ball joint is not
accomplished, the result is a limitation of the neces-
sary ball stud movement. If ball stud movement is
limited, an interference between the ball stud and
housing is created, and binding or even fracture may
occur. Replacement ball joints may or may not have
marking notch as shown in Figure
3A-20. If it does
not have a marking notch, the joint is completelysymetrical and may be installed in any position.
When pressing in ball joint do not press on bottom
plate, but on ball joint housing only.2. Install dust cap on lower ball joint and fill with
chassis lubricant. Attach dust cap retainer.
3. Press ball joint into steering knuckle. Use
J-9519-3 as installer and J-21690 as a supporting
sleeve.4. Install castle nut on ball joint stud and torque to
40
Ib.ft. Install new cotter pin.
5. Reconnect shock absorber to lower control arm
and torque to 30 lb.ft.
6. Remove spring compressor.
7. Install front wheel, and lower the car.
8. Always check caster and camber after ball joint
replacement.
Installation Opel 1900 - Manta
CAUTION:
Fasteners are important attachingparts in
that they could
aff’ect the performance of vital com-
ponents and systems, and/or could result in
ma&r
repair expense. They must be
rep/aced with one of
the same part number or with equivalent parts, if
rep/acement becomes necessary. Do not use a re-
p/acement part of lesser quality or substitute design.
Torque valves must be used as
specitied during reas-
sembIy to assure proper retention of these parts.1. Drive new ball joint into lower control arm using
Tools J-9519 as installer and J-23755 as a supporting
sleeve. Do not strike onto ball joint bottom.
The ball joint is maintenance-free. It is supplied as an
assembly only and cannot be disassembled further.
2. On new lower control arm ball joint, make sure
that the marking groove in the housing bottom in
alignment with the axis of the lower control arm.
Permissible deviation: minus 2 degrees to plus 2 de-
grees.This is required, to obtain the maximum freedom of
movement of the ball stud in the housing. See Figure
3A-18.3. Attach steering knuckle together with front wheel
hub and brake caliper to lower control arm ball joint.
Torque castle nut to 54
ft.lbs.4. Attach ball joint to upper control arm and torque
to 29
ft.lbs. Always use new self-locking nuts.
5. Install wheel and tighten nuts to a torque of 65
ft.lbs.6. Lower car and check caster and camber.

FRONT SUSPENSION3A- 11UPPER CONTROL ARM SHAFT
INNER SLEEVE
OUTER SLEEVE
RUBBER DAMPENIN
GUIDE SLEEVE
ABSORBER SUPPOR
SHOCK ABSORBER SUPPORT
ON FRONT SUSPENSION
CROSS MEMBER
-TOOTHED WASHER
l-UPPER CONTROL ARM
RUBBER BUSHINGS
PLATE WASHER
Figure
3A-19 Upper Control Arm Shaft and Bushings
placement part of lesser quality or substitute design.
Torque
valves must be used as specified during reas-
semb/y to assure proper retention of these parts.1. On installation of the upper control arm, make
sure that damper bushing with the rubber shoulder
on both sides is always located in the rear.
2. Attach upper control arm to cross member and
torque to
40 lb.ft. Always use new self-locking hex
nut. The upper control arm must be tightened in
horizontal position only. This applies also to all other
attaching joints in connection with rubber damper
bushings in the control arms of the front suspension
so that the rubber parts under load are in an almost
twist-free condition. This position exists, if the hooks
J-23697 are used.
3. Attach ball joint to upper control arm and torque
to 29
lb.ft.4. Install wheel and torque nuts to 65
lb.ft. Lowercar.LOWER CONTROL ARM REMOVAL AND
INSTALLATION
Removal GT
1. Raise car and support at rear of front frame rails.
2. Remove front wheel.
3. Remove cotter pin from castle nut on ball joint
stud and back off castle nut two (2) turns. Hit ball
stud a sharp blow to break it loose. DO NOT
REMOVE NUT.
4. Install spring compressor (J-21689) and compress
spring until a distance of
3-l/8 inches is achieved
between spring compressor and lower spring leaf.
5. Disconnect and compress shock absorber.
6. Support rail of spring compressor with a jack.
Remove lower control arm from frame cross mem-
ber. Nuts may have to be removed with a punch. See
Figure 3A-20. Discard the lock nuts.
7. Remove lower ball joint stud nut. Slightly lower

FRONT SUSPENSION3A- 13
6. Reconnect shock absorber to lower control arm
and torque to 30
Ib.ft.7. Remove spring compressor.
8. Install front wheel, and lower the car.
9. Check front end alignment.
Installation Opel 1900 Manta
CAUTION: Fasteners are important attachingparts in
that they could aff&
the-performance of vitaI com-
ponents and systems, and/or could
resu/t in major
repair expenses. They must be
repraced with one of
the same part number or with an
equivaknt part, ifreplacement becomes necessary. Do not use a re-
placement part of ksser quality or substitute design.
Torque values must be used as specified
dmitig reas-
sembIy to assure proper retention of these parts.1. Loosely attach lower control arm to front cross
member.
2. Properly seat spring between lower control arm
and cross member.
3. Raise jack and place lower control into position.
4. Attach lower control ball joint to steering knuckle
and torque nut to 54
Ib.ft.5. Tighten lower control arm to cross member bolt
to 43
lb.ft.6. Attach stabilizer bar to lower control arm and
torque to 87
lb.ft.7. Attach stabilizer bar to cross member to body
support.
8. Install shock absorber and torque lower attaching
nut and bolt to 30
lb.ft.9. Install nuts on upper shock absorber attaching
studs. Tighten nuts until a distance from top of nut
to stud is approximately
l/2 inch.
10. Install front wheels and tighten nuts to 65
lb.ft.11. Remove stands and lower car.
STEERING KNUCKLE REMOVAL AND
INSTALLATION
Removal GT1. Raise car and support with stands.
2. Remove wheel nuts. Remove wheel assembly.
Figure 3A-2 1 Caliper Attachment4. Remove spindle grease cap. Remove cotter pin
and spindle nut. Remove wheel hub with disc.
5. Install J-21689 spring compressor and compress
spring until 3-l/8” clearance is obtained between
spring compressor and lower spring leaf.
6. Remove upper ball joint using tie rod remover,
J-
21687.7. Remove shock absorber at lower attachment only.
8. Remove lower ball joint using J-21687 remover
and remove steering knuckle. Remove dust shield
from steering knuckle.
Removal Opel 1900. Manta1. Raise car and support with stands.
2. Detach brake caliper and steering arm from steer-
ing knuckle.
3. Remove castle nut cotter pin, unscrew nut and
pull steering knuckle off upper control arm ball joint.
4. Unscrew brake caliper and suspend it in wheel
house.5. Remove front wheel hub.
6. Unscrew steering arm and brake cover plate from

FRONT SUSPENSION3A- 15
SHOCK ABSORBER REMOVAL ANDINSTALLATION
Removal
Opel 1900. Manta1. Raise car and support with stands.
2. Remove upper attaching nuts from shock ab-
sorber.3. Remove lower attaching nut, lockwasher, and
bolt.
4. Compress shock absorber and remove from car.
Removal GT1. Remove air cleaner. See Figure 3A-24.
Figure 3A-24 Removal of Air Cleaner
2. Remove plastic cover over shock absorber upper
attachment.
3. Raise car and support with stands.
4. Remove upper attaching nuts from shock ab-
sorber.5. Remove lower attaching nut, lockwasher, and
bolt.
6. Compress shock absorber and remove from car.
Installation Opel 1900. Manta1. Inspect shock absorber for damage and seal leaks.Always replace the upper and lower rubber grom-
mets when replacing a shock absorber.
2. Install the lower grommet retainer and grommets
on shock absorber. Compress shock absorber and
place in position.
3. Install lower attaching bolt and nut. Torque to 30
lb.ft.4. Install nuts on upper attaching studs. Tighten nuts
until distance from top of nut to stud is approxi-
mately
l/2 inch. See Figure 3A-25.5. Install plastic cover.
Installation GT1. Inspect shock absorber for damage and seal leaks.
Always replace the upper and lower rubber grom-
mets when replacing a shock absorber.
2. Install the lower grommet retainer and grommets
on shock absorber. Compress shock absorber and
place in position.
3. Install lower attaching bolt and nut. Torque to 30
lb. ft.
4. Install nuts on upper attaching studs. Tighten nuts
until distance from top of nut to stud is approxi-
mately
l/2 inch. See Figure 3A-25.5. Install plastic cover.
6. Install air cleaner.
FRONT SPRING REMOVAL AND INSTALLATION
Removal (GT)1. Raise car and support at rear of front frame rails
with stands.
2. Remove front wheels.
3. Remove cotter pin from castle nut on lower ball
joint studs and back off castle nut two (2) turns. Hit
ball stud a sharp blow to break it loose. Do not
remove nut.4. Install J-21689 spring compressor and compress
the spring until 3-l/8” clearance is obtained between
spring and compressor.
5. Disconnect both shock absorbers at their lower
attachment. Compress both shock absorbers.
6. Support the rail of J-21689 Spring Compressor
with a jack. Remove lower control arm to cross
member attaching nuts and bolts.

FRONT SUSPENSION3A- 17Torque values must be used as specified during reas-
sembly to assure proper retention of these parts.1. Attach lower control arm to front spring eye.
Torque bolts to 18
lb.ft.2. Install spring compressor on spring and compress
spring to appropriate length.
3. Raise jack with spring compressor, spring and
control arm assembly into position under the car.
4. Install lower ball joints and torque nuts to 54
Ib.ft.Install new cotter pin.
5. Attach lower control arms to frame cross member
using new lock nuts.
6. Attach both shock absorbers. Torque bolts to 30
lb.ft.7. Remove spring compressor.
8. Install front wheels.
On replacement of the damper bushings on the front
springs, only the one-part damper bushing is in-
stalled for either the two-leaf or three-leaf spring.
For proper location of the marking lugs, see Figure3A-26.
Installation (Opel 1900. Manta)
CAUTION: Fasteners are important attachingparts in
that they
co&d 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. Properly seat spring between lower control arm
and cross member.
2. Raise jack and place lower control into position.CROSS SECTION
SA-26Fig. 3A-26 Front Spring Damper Bushing.
3. Attach lower control ball joint to steering knuckle
and torque nut to 54
lb.ft.4. Tighten lower control arm to cross member bolt
to 43 lb.ft.
5. Attach stabilizer bar to cross member to body
support.
6. Install shock absorber and torque lower attaching
nut and bolt to 30
lb.ft.7. Install nuts on upper shock absorber attaching
studs. Tighten nuts until a distance from top of nut
to stud is approximately
l/2 inch.
8. Install front wheels and tighten nuts to 65
lb.ft.9. Remove stands and lower car.
SPECIFICATIONSBOLT TORQUE AND FRONT END ALIGNMENT

3A- 161973 OPEL SERVICE MANUAL
SPECIFICATIONS
Torque Specifications
Use a reliable torque wrench to tighten all parts listed to insure proper
tightness without straining or distorting parts. These specifications are for
clean and lightly-lubricated threads only; dry or dirty threads produce in-
creased friction which prevents accurate maasurement of tightness.
LocationFront Suspension Crossmember to Front Frame
Clamp, Steering Mast to Steering Mast Flange
(GT)
........................................................................................
Clamp, Steering Mast to Steering Mast Flange(1900
-Manta)..................................................................
Clamp,UpperUniversalJoint(GT)..................................Clamp, Lower Universal Joint (GT)
..................................
WheelNuts............................................................................Lower Control Arm Shaft to Lower Control Arm
..........Lower Control Arm Ball Joint to Steering Knuckle
......Upper Control Arm Ball Joint to Steering Knuckle
(GT)........................................................................................Upper Control Arm Ball Joint to Steering Knuckle
(1 900 Manta)
..................................................................Upper Control Arm Ball Joint to Upper Control Arm
ShockAbsorbertoLowerControlArm..........................Steering Arm to Steering Knuckle (1900
- Manta)......
Brake Backing Plate or Brake Disc Shield andSteering Arm to Steering Knuckle
(GTJ
Hex Head Bolt M 10......Hex Head Bolt M 8
......
Brake Backing Plate to Steering Knuckle(1900 Manta)
..................................................................
Brake Caliper to Steering Knuckle.................................
Lower Control Arm to Front Spring Eye (GT)................
Brake Disc to Front Wheel Hub........................................Upper Control Arm to Crossmember (1900
- MantajLower Control Arm to Crossmember (1900
- Manta)
Steering Gear Housing to Front Suspension
Crossmember (GT)
............................................................
Steering Gear Housing to Front SuspensionCrossmember (1900
- Manta)........................................Stabilizer Bar to Lower Control Arm
(Opel 1900
- Manta)........................................................Tie Rod Clamp Bolts
(GTJ....................................................
CastleNut,TieRodtoSteeringArm..............................Upper Control Arm Shaft to Shock Absorber Support
and Upper Control Arm (GT)
..........................................
CrossMember to
BodySupport Attachment................
FrontSuspensionAssemblytoFrame............................Front End Alignment Specifications
Torque
Lb.Ft.36
1522
14
22
6540
5429
ii30
5847
18
58
72
1836
40
43
1830
87
:i33
58
47ModelCaster’
Camber”1900‘3
l/2-6 l/2GT
3+1-:%+*Permissible deviation from left to right wheel
- Max. 1’.
Toe-In”Min.-Max.
l/8-3/ 16
l/32-1/8Outer Wheel
When Inner
Wheel at 20
19
l/418
l/2