1973 OPEL MANTA transmission

Installation1. FLYWHEEL
2. CLUTCH ASSEMBLY
3. ASSEMBLY MARKS
4. CLUTCH ALIGNING
ARBOR J-229347A-51. Slide control cable ball end through eye in clutch
housing. Connect to lever and (on GT) install return
spring.
2. Replace washers and rubber grommet, slide cable
through retainer on dash panel, and connect to
clutch pedal. To adjust, refer back to Clutch Adjust-
ment paragraph
c or d.
Figure
7A-5 Clutch Installation
SPECIFICATIONS
GENERAL SPECIFICATIONSE-l
I-‘-J- : ,“/’‘~Clutch Specifications
Type. . . . . . . . . . . . . . . . . . . .
Pedal Lash
_ 3/4” to l-1/4”-. -..-.
.........Single Plate - Dry Disc
unvenFlareuamerer.....................................................................................................6-3/4”
Driven Plate Facings
......................................................................................Woven Asbestos
Number of Facings
....................................................................................................................
2Facing Attachment
........................................................................................................Riveted
Vibration Dampening
..................................................................................4 Torsional Springs
Bolt Tightening SpecificationsCLUTCH CONTROL CABLE REMOVAL AND
INSTALLATION
(SEE FIGURE 7A.6
OR 7A-7)
If a new cable was installed or the cable adjustment
was changed during an operation, x-adjust cable
afterwards.
Removal
1. Disconnect return spring and cable with ball end
from release lever. Slide control cable out of eye in
clutch housing.
2. With a screwdriver, pry E-ring out of groove in
control cable, at tirewall, and disconnect cable from
clutch pedal.
3. Pull cable out of retainer on dash panel and
remove washers and rubber grommet.
PartLocationTorque
Lbs.Ft..’
BoltFlywheeltoCrankshaft........................................................43
/BoltClutchCovertoFlywheel....................................................36
BoltTransmissiontoClutchHousing......................................32.36;:
BoltStartertoClutchHousing..................................................40
NutSupport to Clutch Housing................................................4IBoltIntake and Exhaust Manifold to Cylindei Head............33

7B- 121973 OPEL SERVICE MANUAL
MANUAL TRANSMISSION
CONTENTS
Subject
DESCRIPTION AND OPERATION:
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Power
Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DIAGNOSIS: (Not Applicable)
MAINTENANCE AND ADJUSTMENTS:
Adjusting
ReverseGearshiftBlocker. . . . . . . . . . . . . . . . . . . . . . . . . .Shift Lever Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ServicingGearshift
Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .MAJOR REPAIR:
Transmission
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installation
ofTransmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing and Installing
Speed0 Driven Gear
(Transmission
Removed). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ReplacingBushinginSelectorLever. . . . . . . . . . . . . . . . . . . . . . . . . .Transmission
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Transmission
Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPECIFICATIONS:
Specifications ..,....._....,......,.....,......,.,.....,,.,..,......,.,....,........
Page No.
78-12
7B-13
78-1978-l
9
7B-19
78-22
78-22
78-23
78-23
78-23
78-28
78-33

MANUAL TRANSMISSION78.13POWER FLOWIST
& 2ND GEAR
SLIDING GEARr2yDmSPEEDGEAR
1ST SPEED
GEAR ‘EREVERSE
-IDLER GEAR
COUNTERSHAFT GEAR
+/UNIT
- IST SPEED GEAR~LCOUNTERSHAFT GEAR UNITCOUNTERSHAFT GEAR UNIT
f-t3RD SPEED GEAR
REVERSE SPEED GEARCOUNTERSHAFT GEAR
UNIT - 2ND SPEED GEAR
POWER FLOW. NEUTRAL POSITION
Figure 78.1
Neutral PositionDRIVE(INPUT1
ERSHAFT
R UNIT
‘E GEAR
78-lThe countershaft gear unit and the mainshaft lst,
Znd, and 3rd speed gears are all idling in “Neutral”
position. The reverse idler gear is not engaged or in
mesh with any gear and, therefore, it is idle.

7B- 141973 OPEL SERVICE MANUAL
POWER FLOW - 1st SPEED
MAIN DRIVE GEAR (INPUT)
COUNTERSHAFT GEAR UNIT 1st SPEED GEAR
1 st SPEED GEAR
1st AND 2nd GEAR SLIDING GEAR1st AND 2nd SPEED SLIDING GEAR GUIDE UNITCOUNTERSHAFT GEAR
UI‘!IT DRIVE GEAR1st SPEED GEAR1st AND 2nd GEAR SLIDING GEAR
,st AND 2nd SPEED SLIDING GEAR GUIDE UN1MAINSHAFT (OUTPUT)
70-2Figure 78.2
First SpeedAfter synchronizing the speeds of the mainshaft and
the 1st speed gear, the 1st and 2nd gear sliding gear
shifts to the rear of the transmission and locks the 1st
speed gear to the mainshaft through the 1st and 2nd
speed sliding gear guide unit. This 1st and 2nd speed
sliding gear guide unit is internally splined to the 1st
and 2nd gear sliding gear and is
exl~ernally splined to
the mainshaft. Both the 3rd speed gear and the 2nd
speed gear are idling. The reverse idler gear is not
engaged with any gear and, therefore, it is idle.
With a 1st speed gear ratio of
3.428:1, the main drive
gear (input) must turn 3.428 revolutions for every
one revolution of the main shaft (output).
IT

MANUAL TRANSMISSION76.15POWER FLOW. 2nd SPEED
MAIN DRIVE GEAR (INPUT)
COUNTERSHAFT GEAR UNIT 2nd SPEED GEAR
2nd SPEED GEAR
1st AND 2nd GEAR SLIDING GEAR
1st AND 2nd SPEED SLIDING GEAR GUIDE UNITCOUNTERSHAFT GEAR UNIT DRIVE GEAR
2nd SPEED GEAR
1st AND 2nd GEAR SLIDING GEAR
Ist AND 2nd SPEED SLIDING GEAR GUIDE UIMAINSHAFT (OUTPUT)
76Figure 78.3
Second SpeedAfter synchronizing the speeds of the mainshaft and
the 2nd speed gear, the 1st and 2nd gear sliding gear
shifts toward the front of the transmission and locks
the 2nd speed gear to the mainshaft through the 1st
and 2nd speed sliding gear guide unit. This 1st and
2nd speed sliding gear guide unit is internally splined
to the 1st and 2nd gear sliding gear and is externally
splined to the mainshaft. Both the 3rd speed gear and
the 1st speed gear are idling. The reverse idler gear
is not engaged with any gear and, therefore, it is
idle.
With a 2nd speed gear ratio of
2.156:1, the main
drive gear (input) must turn 2.156 revolutions for
every one revolution of the mainshaft (output).
VIT
i-3

78. 161973 OPEL SERVICE MANUAL
POWER FLOW
- 3rd SPEED
MAIN DRIVE GEAR (INPUT)
COUNTERSHAFT GEAR UNIT 3rd SPEED GEAR
3rd SPEED GEAR
GEAR SHIFTER SLEEVE
GEAR SHIFTER SLEEVE CARRIERCOUNTERSHAFT GEAR UNIT GEAR DRIVE
3rd SPEED GEAR
GEAR SHIFTER SLEEVE
GEAR SHIFTER SLEEVE CARRIER
MAIN SHAFT (OUTPUT)
78-4
Figure 78.4
Third Speed
After synchronizing the speeds of the mainshaft and
the 3rd speed gear, the gear shifter sleeve shifts to the
rear of the transmission and locks the 3rd speed gear
to the mainshaft through the gear shifter sleeve car-
rier. This gear shifter sleeve carrier is internally
splined to the gear shifter sleeve and is externally
splined to the mainshaft. Both the 1st speed gear and
the 2nd speed gear are idling. The reverse idler gear
is
not engaged with any gear and, therefore, it is
idle.
With a 3rd speed gear ratio of
1.366:1, the main drive
gear (input) must turn 1.366 revolutions for every
one revolution of the mainshaft (output).

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.