1973 OPEL GT-R steering

FRONT SUSPENSION3A- 5
Figure 3A-6 GT Steering Mast Joint
2. Install Hooks J-23697 before jacking up car to
assure proper loading of suspension bushings and
mounts. See Figure
3A-7.3. Raise front of vehicle and support with stands.
4. Remove front wheels.
5. Remove guard plate. See Figure
3A-8,6. Remove brake line retainers on both sides. The
brake system remains closed. Unscrew brake calipersand suspend them in wheel house.Figure
3A-9 Removing Guard Plate
7. Suspend engine with a suitable engine lifter, simi-
lar to the one shown in Figure
3A-9.8. Unscrew lower steering mast clamp bolt out of
pinion flange. See Figure
3A- 10.
9. Unscrew front left and right engine mount from
damper block.
10. On top and in the rear, unscrew front suspensionFigure
3A-7 Installing Hooks J-23697Figure 3A-9 Suitable Engine Liftel

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.

3A- 101973 OPEL SERVICE MANUAL
Figure 3A-18 Lower Ball Joint Notch Opel 1900 -
MantaUPPER CONTROL ARM REMOVAL AND
INSTALLATION
Removal GT1. Raise car and support at rear of front frame rails.
2. Remove front wheel.
3. Install spring compressor and compress spring
until there is 3-l/8” between compressor and lower
spring leaf.
4. Remove cotter pin and castle nut from upper ball
joint stud. Discard cotter pin.
5. Use tie rod remover J-21687 remove ball jointfrom.steering knuckle. 6. Support brake drum to
relieve tension on brake hose.
7. Remove hex nut from upper control arm shaft.
Remove shaft and washers from shock absorber sup
port. Do not damage threads on control arm shaft.
8. Remove control arm from car. Do not lose inner
toothed washers. Note size and location of toothed
washers.Removal
Opel 1900 . Manta
1, Raise car and support at rear of front frame rails.
2. Remove front wheel
3. Unscrew upper control arm to cross member
self-locking attaching nut.4. Unscrew ball joint from upper control arm. Do not
turn upper control arm ball joint flange, as this
would result in a change of camber.
5. Support front wheel hub so that brake hose is not
stressed.6. Pull out upper control shaft to cross member at-
taching bolt and remove control arm. Shims have to
be reinstalled in their original location to maintain
the proper caster setting.
Installation GT
CAUTION:
Fasteners are important attaching parts in
that they could affect the the
perfonmmce of vital
components and systems, and/or could result in ma-
jor 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 specified during reas-
sembly to
assure proper retention of these parts.If rubber bushings on control arms are worn, arms
must be replaced.
1. Slide rubber rings over bushings. Slide rings over
inner sleeves of bushings. Place control arm in posi-
tion on shock absorber support, installing toothed
washers in their original positions. See Figure 3A-
19.2. From front to rear, install control arm shaft. If
necessary, align washers and control arm bushings
with a small drift prior to installing control arm
shaft. See Figure
3A-19.3. Tighten hex nut on control arm shaft finger tight.
4. Increase tension on spring compressor in order to
relieve tension on control arm shaft. Then torque hex
nut on control arm shaft to 33
Ib.ft.5. Press ball joint stud into steering knuckle and
torque castle nut to 29 lb.ft. Install new cotter pin.
6. Remove spring compressor and lower car.
7. Check front end alignment.
Installation Opel 1900. Manta
CAUTION:
Fasteners are important attaching parts in
that they could at?&
the performance of vital 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 equivalent parts, if
replacement becomes necessary. Do not use a
re-

3A- 121973 OPEL SERVICE MANUAL
Figure 3A-20 Lower Control Arln Attachment
jack so that spring and lower control arm assembly
is removed from the front cross member and steering
knuckle.
8. Lower jack, spring compressor, and front spring
with control arm assembly. Remove lower control
arm to spring nuts.
9. Release spring compressor and remove controlarm attaching bolts and control aRn.
Removal Opel 1900. Manta1. Prior to raising car, install upper control arm
hooks J-23697.
2. Raise car and support with stands. Hoist should
be left in the raised position to maintain pressure on
lower control arm.
3. Remove front wheel.
4. Detach both stabilizer supports from cross mem-
ber to body support.
5. In lower control arm, remove self-locking hex
head bolt from stabilizer support and remove
washer.6. Using a pry bar, pry stabilizer bar out of lower
control arm support.
7. Remove shock absorber.
8. At lower control arm ball joint, remove castle nut
cotter pin and remove nut.
9. With suitable drift, detach lower control arm ball
joint from steering knuckle.10. Loosen nut that retains lower control to front
cross member.
11. Slowly lower hoist to release spring tension.
12. Swing lower control arm downwards and remove
front spring.13. Remove nut that retains lower control arm to
front cross member and remove lower control arm.
Installation GT
CAUTION:
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 expeme. 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 parts1. Attach lower control arm to front spring eye.
Torque bolts to 18
1b.R.2. Install spring compressor and with a jack raise
spring compressor with spring and control arm as-
sembly into position for pressing ball joint into steer-
ing knuckle.
3. Press ball joint into steering knuckle. Use
J-;lYN;: as installer and J-21690 as a supporting
4. Install castle nut on ball joint stud and torque to
54
lb.ft. Install new cotter pin.
5. Attach lower control arm to frame cross member
using new lock nuts.

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

3A. 141973 OPEL SERVkE MANUAL
Figure 3A-22 Caliper Removed and Hung by Wire
steering knuckle. Swing steering arm and tie rod to
the side.7. Remove castle nut cotter pin, unscrew nut and
pull steering knuckle off lower control arm ball joint.
Installation GTCAUTION: Fasteners are important attachingparts in
that they could affect the performance of
viral 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
desig.Torque values must be used as specified during reas-
sembly to assure proper retention of these parts.
1. Always replace paper gasket when installing dust
shield on steering knuckle. Lightly coat both surfaces
of paper gasket with chassis lubricant before installa-tion and torque attaching bolts to 47
lb.ft.2. Install lower ball joint in steering knuckle. Torque
castle nut to 54
Ib.ft. Install new cotter pin.
3. Attach shock absorber at lower end. Torque boltsto 30 lbs. ft.
4. Install upper ball joint. Torque castle nut to 29
lb.ft. Install new cotter pin.
5. Remove spring compressor.6. Install hub and disc on spindle and tighten spindle
nut as stated under MAINTENANCE AND AD-
JUSTMENTS in this section.
7. Install caliper on steering knuckle and torque boltsto 72
lb.ft. See Figure 3A-21.8. Install wheel and torque wheel nuts to 65
lb.ft.
Installation Opel 1900
- MantaCAUTION: Fasteners are important attachingparts in
that they could
affit the performance of vital com-
ponents and systems, and/or could result in
ma&repair expense. They must be replaced with one of
the same part number or with equivalent parts, ifrepfacement 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. Attach steering knuckle to lower control arm ball
joint. Torque castle nut to 54
lb.ft.
2.
Atl,ach brake cover plate and steering arm to steer-ing knuckle. If required, install new paper gasket
between cover plate and steering knuckle. Care for
proper seat of T-head bolts. See Figure
3A-23.Figure 3A-23 Attaching Brake Cover Plate
3. Install front wheel hub and brake caliper.
4. Attach steering knuckle to upper control arm ball
joint. Torque castle nut to 40
lb.ft.5. Steering arm to steering knuckle
_ 58 lb.ft.6. Brake caliper to steering knuckle
- 72 lb.ft.7. Adjust front wheel bearing clearance.
8. Remove stands and lower car