1973 OPEL MANTA Service Manual

48. 181973 OPEL SERVICE MANUAL
Figure 48.26 Checking Torque
to Rotate Gear
in;! surfaces are free of burrs or foreign material.
Tighten bolts to 47 lb.ft.
10. Check lateral runout of installed ring gear. Max-imum permissible runout is
.003”. If runout is
greater than specified, make certain that dirt or burrsare not holding the ring gear in a cocked position on
the case and that the bolts are evenly
torqued.Figure 48-27 Installing Differential Side Bearings
g. Install shim packs with respective side bearing1 I.
In.stall side bearings using installer J-22919 and
drive handle J-8092. Support opposite side of case on
pilot J-2241-1
1 to prevent bearing damage. See Fig-ure
4B-27.12. Determine differential side bearing preload and
backlash as follows:
a. Position differential case assembly less side bear-
ing shims into the side bearing bores of the carrier.
See Figure
4B-28.Figure 48.28 Installing Differential Case Assembly
b. Using two sets of feeler gauges, insert feeler stockof suffcent thickness between each bearing outer
race and the carrier to remove all end play. Make
certain the feeler stock is pushed to the bottom of thebearing bores. See Figure
4B-29.
c. Mount dial indicator J-8001 on carrier so indicator
stem is at right angles to a tooth on the ring gear. SeeFigure
4B-29.d. Adjust feeler gauge thickness from side to side
until ring gear backlash is ,004” to
.OO8” (.005” is
desired).e. With zero end play and correct backlash estab-
lished, remove feeler gauge packs, determine thick-
ness of shims required and add ,002” to each shim
pack to provide side bearing preload.
f. Remove case assembly and both side bearings us-ing J-22588 with adapter leg J-22939 and pilot
J-
2241-l 1.

REAR AXLE48.19FEELER
DIAL INDICATORDIFFERENTIAL
Figure 48.29 Removing Differential Case and End Playusing installer J-22919, driver handle J-8092 and pi-
lot J-2241-11.16. Install torque tube assembly.
17. Install axle shafts.
13. Position case assembly and outer races in the
carrier. Use a soft faced hammer to drive the case
into the carrier until the side bearing outer races
bottom in their bores.Assynbly and Installation of Differential Case
- GT
14. Install side bearing caps in their original location
and torque the bolts to 33
Ib.ft.
1. Lubricate the thrust washers, side and pinion gears
and install the side gears with respective thrust wash-
ers in the differential case.
15. Rotate case assembly several times to seat the
bearings. Check backlash and preload using a torque
wrench on a ring gear attaching bolt. See Figure
4B--68. Torque required to turn case should be 20 to 30
lb.in. for new bearings or 10 to 20 Ibin. for used
bearings. If torque is not correct, it will be necessary
to reshim the side bearings.2. Install the pinion gears and thrust washers be-tween the side gears 180 degrees apart and rotate the
gears as an assembly until the pinion gear bores are
aligned with pinion shaft bores in the case.
3. Install pinion shaft so that the lock pin hole in the
shaft aligns with the lock pin hole in the case.

49- 201973 OPEL SERVICE MANUAL
IN.LB. TORQUE
Figure 48.30 Checking Side Bearing Preload
4. With the use of a feeler gauge, check clearance
between differential side gears and case. See Figure
4B-31. Clearance should be ,003” to X106”. If clear-
ance is not within these limits, remove side gears and
install shims of correct thickness to obtain desired
clearance, reassemble and install pinion shaft lock
pin.
Figure 48.31 Checking Side Gear to Case Clearance
5. Install ring gear on case, making certain their
mating surfaces are free of burrs or foreign material.
Tighten bolts to 47
lb.ft.
6. Check lateral runout of installed ring gear. Max- imum permissible

runout is X03”. If runout is
greater than specified, make certain that dirt or burrs
are not holding the ring gear in a cocked position on
the case and that the bolts are evenly torqued.
7.
Imtall side bearings using Installer J-22919 and
Drive Handle J-8092. Support opposite side of case
on Pilot J-2241-1 1 to prevent bearing damage. See
Figure
4B-32.
DRIVER
HANDLE
J-8092
4B.27
Figure 48-32 Installing Differential Side Bearings
Figure
48.33 Installing Differential Case Assembly

REAR AXLE48.21FEELER
DIFFERENTIAL
DIAL INDICATOR
SIDE BEARINGS
Figure 48.34 Removing Differential Case and End
Play8. Determine differential side bearing preload and
backlash as follows:d. Adjust feeler gauge thickness from side to side
until ring gear backlash is
004” to ,008” (.005” is
desired).a. Position differential case assembly less side bear-
ing shims into the side bearing bores of the carrier.
See Figure
4B-33.b. Using two (2) sets of feeler gauges, insert feeler
stock of sufficient thickness between each bearing
outer race and the carrier to remove all end play.
Make certain the feeler stock is pushed to the bottomof the bearing bores. See Figure
4B-34.
e. With zero end play and correct backlash estab-
lished, remove feeler gauge packs, determine thick-
ness of shims required and add
.002” to each shim
pack to provide side bearing preload.
f. Remove case assembly and both side bearings us-
ing J-22588 with Adapter Leg J-22939 and Pilot
J-
2241-11.c. Mount Dial INDICATOR J-8001 on carrier sog. Install shim packs with respective side bearing
indicator stem is at right angles to a tooth on the ring
using Installer J-22919, Driver Handle J-8092 and
gear. See Figure
4B-34.Pilot J-2241-1 1.

48. 221973 OPEL SERVICE MANUAL
9. Position
case assembly and outer races in the car-
rier. Use a soft-faced hammer to drive the case into
the carrier until the side bearing outer races bottom
in their bores.
10. Install side bearing caps in their original location
and torque the bolts to 33
lb.ft.IN. LB. TORQUL
11. Rotate case assembly several times to seat the
bearings. Check backlash and preload using a torque
wrench on a ring gear attaching bolt. See Figure 4B-
35. Torque required to turn case should be 20 to 30
Ib.in. for new bearings or 10 to 20 lb.in., for used
bearings. If torque is not correct, it will be necessary
to r&him the side bearings.
12. Insta!l torque tube assembly.
13. Install axle shafts.Figure 48.35 Checking Side Bearing
Preload
SPECIFICATIONS
DIFFERENTIAL SPECIFICATIONS
General SpecificationsRear Axle Type
.,,...,,,...,,_...._..,,...,,,...,,,....,,.,...,,.,,...,,..,,,........................ Semi-Floating Hypoid
Rear Axle Oil Capacity
..____,,...,,,...,.,..,............,,..,,..,,................................................. 2 l/2 7’.Ring and Pinion Gear Set Type
. . . . . . . . . . . . . . . . . .._................................................................Hypold
Axle Ratios

REAR AXLE49.23
Adjusting end Fitting SpecificationsPinionBearingPreloadWith
NewBearings. . . . . . . . . . . . . . . . . . . . . . . . . .7-13Lb.In.
Preload With Reused Bearings
__.._..I...................,.................,,...................,,............ 5-8 Lb.In.
Pinion Depth Setting
.002” to -.OOl’ from pinion marking using following selective shims:
Number of Notches
Thickness In.in Circumference.0097Flattened on One Side
.00980
.01081
.01182
.01283
.01384
.01485Clearance Between Differential Side Gears and Case Max.
,000” on the Opel 1900 andManta and
,006” on the GT using the following selective shims:
Thickness In.
1900
,039.04
1,043,045,047,049.05
1,053,055
GT
.0394
.0433
.0473Number of Notches
in Circumference
0
1
2
.05123Max. Permissible Axle Shaft Bearing Seat Radial Runout
.._......................................... ,002”Max. Permissible Rear Axle Shaft Flanze Lateral Runout . .
,004” at Lareest Flange Dia.
Max.Permissible Lateral Ring Gear R&out
._.._,,.........._.....,........................... T . . . . . . . . . . . ...” ,003”RingGearandDrivePinionBacklash
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .,004”-.008”
Differential Side Bearing Preload New, Bearings
- 20-30 Lb.In.; Used Bearings - lo-20Lb.In., using following selective shims:
Thickness In..0059.0069
.0079
.0089
.0098
.0108
.0197
.0433Number of Notches
in Circumference
0
1
;
4
5
8
7
Torque SpecificationsUse a reliable torque wrench. Specifications are for clean and lightly-oiled
threads.

49- 241973 OPEL SERVICE MANUAL
Torque
Lb.Ft.
1.9Nut and BoltPropshaft to Drive Pinion Shaft Extension Flange
......11
NutFlange
toDriveShaftExtension........................................87
BoltRing Gear to Case................................................................
BoltSideBearingCaptoCarrier.............................................i;
BoltDifferentialHousingCover.................................................22
NutTrackRodAttaching(GT)....................................................40
Nut and BoltStabilizer
RodtoRearAxleShackle................................25
BoltStabilizer Rod to Body........................................................15
NutTrack Rod to Rear Axle (Opal1900 & Manta)..............76
NutTrack Rod to Side Member (Opel 1900 & Manta)......22
10 MM Bolt Nut
....................................................................................................................368 MM Bolt Nut
......................................................................................................................156 MM Bolt Nut
........................................................................................................................5

DIFFERENTIAL COVER AND
SIDE BEARING CAPCOVER GASKET
DRIVE PINIONSlDE,BEARlNG /; GEAR REAR PINION BEARINGx
\PRELOAD NUT, DIFFERENTIAL CASE
SIDE GEAR
PINION GEAR
THRUST WASHER
AXLE SHAFT
BEARING RETAINER
FLAT WASHER
TORQUE TUBE40.37PRdPELLER SHAFT
Figure 48-37 Exploded View Rear Axle Assembly