Opel 1900 1973, Service Manual, Page: 390 / 625

MANUAL TRANSMISSION
Using external snap ring pliers, secure gear shifter
sleeve carrier on mainshaft with snap ring. See Fig-
ure
6. From rear of mainshaft, slide second speed gear
onto mainshaft. Gear must turn freely on mainshaft.
See Figure
SPEED
GEAR CONE\
3RD SPEED
GEAR
M A I N
SYNCHRONIZER
V E R
2ND SPEED
GEAR
Figure Second Speed Gear and Synchronizer
Ring Installed
7. Place second speed synchronizer cover onto sec-
ond speed gear cone. See Figure
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
9. Press 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 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, speed gear, mainshaft washer
(chamfer toward rear), and mainshaft bearing snap
ring onto mainshaft.
13. Press on mainshaft inner bearing using Tool
22913. See Figure
GUIDE UNIT
SPRING
Figure Both Clutch Key Springs Installed
J-22913 MAINSHAFT
ASSEMBLY TOOL
- - - - .
Figure Pressing on Rear Bearing Using Tool
J-22913
14. Insert lock ball in place in mainshaft and place
speedo drive worm gear and 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
shaft bearing snap ring. See Figure