Opel 1900 1973, Service Manual

Page: 393 / 625

Figure 1 Position of Third, Fourth, and Reverse
Intermediate Lever on Selector Shaft
2ND
Figure Position of First and Second
Intermediate Lever on Selector Shaft
3. Install spiral pins to secure both intermediate lev-
ers to the selector shaft. Spiral pins should not be
flush with lever surface, but rather should extend up
between
and inches.
Installing Reverse Speed Shifter Intermediate
Lever and Interlock Balls, Springs, and Plugs
1. Engage reverse speed shifter intermediate lever
with third, fourth, and reverse intermediate lever
and
also
in slot in reverse gear shifter shaft, and install
1973 OPEL SERVICE MANUAL
bedding bolt through reverse speed shifter intermedi-
ate lever and into case. Reverse speed shifter inter-
mediate lever end play on bolt should be between
and inches.
2. Insert both interlock balls and then springs, and
drive both interlock plugs into case holes until they
bottom in interlock plug hole seats. Grooves in plugs
will be showing.
Installing Countershaft Gear Unit
1. Coat thrust washers with ball and roller bearing
grease and stick to transmission case. Lugs of thrust
washers must fit into transmission case slots. See
Figure
2. Turn transmission case extension housing until
gear unit countershaft bore is completely exposed.
3. Place lock ball into shaft and from the rear of the
transmission insert shaft so that thrust washer is held
in position. Hold opposite thrust washer in position
by using a short drift.
4. Insert countershaft gear unit into transmission
case. Be sure all needle bearings and both needle
bearing washers are in place.
5. Insert gear unit countershaft into gear unit and
drive shaft into transmission case while driving out
Special Tool J-2291 1. Pay attention to lock ball. See
Figure
Figure Installing Countergear Shaft
Installing Transmission Case Extension Housing
1. Align transmission case extension housing and
gasket and torque (3) bolts with spring washers to 21
lb. ft.