Overhauling a Opel GT Rear Diff. Unit

I am Now waiting for all the parts to arrive.. from the vendors... sometime this can be a painful experience if parts are held up. Am in the process of undercoating the rear body since all the rear components are now removed..Easier to paint I'll be using a Truck bed liner coating to protect the bottom.
Messy job.. and I'll post some photo's later

Thanks Gary, I'll send over my address ... But good to know the Auto Tranny vents work too

We should buy a bunch I know we sometimes "All"" we Need a new vent.

We pressed the axle bearings onto the shafts with the retainer plates properly positioned and Dust Shield Into Jeff's Homemade Axle Press
It a bit to align everything up before using small bottle jack to press.

I have a good friend Chris who going to help me with the Gear setup install checkout and that will take some time to Go over everything.
I'll be using the Rubber Bushings for Track Rods and Pan H. Rod bar Koni Shocks (Reds)
The Rear Brakes will be Disc Brakes Using VW Calipers and special rotor .. From a German Kit. Nice Brackets

So still need to figure out how to attach a brake line bracket to hold the flexi line each tube to each Caliper... Hose Clamps? Bracket?
and need to extend the Brake Cable tensioner Rod ??

Thanks Gary, The Vent arrived Today, That part should be added to the ""rare"" part list..so hard to find an exact match. Thanks Again
I've been keeping busy while am waiting for the rear to come back with the repaired bearings and gears, then I'll be able to assembly everything, and maybe drive this spring.
I've cleaned and re-under coated the bottom, Installed the rear sway bar and started to install the red Koni's I also Installed the front Big Brakes to the front wqth new SS braided hoses. that came off the Blue GT. My plans are to eventually , replace new bigger master cyl. and booster then replace the hard brake lines.
Also going to replace the complete Exhaust with a 2" SS German system... My winter project ..need to get my butt going...

Started to Install the German Exhaust... getting the old head pipe down and I will post more pictures when I get more work done...

Here is an Update to this project ..that got a little out of a hand.... Life's Moments
I got the rear end Back from the Rebuilder and started installing the axles with the axle shims and new Rear discs Spacers... The kit comes with Nice water jet cut steel laser perfect... Made a pattern for Gary and noted thickness.. It's starting to come together... The Brake Lines have been trouble.. ..

But I got tired of sending parts back and forth to Vendors... Found a local Speed Shop with some cool dudes that knew a lot .. the Audi lines are Bubble Flare and the Opel Lines Are Double Flare and will surely leak.. " Did Nor Know This"" Mum.. Pictured is the Rubber lines ..until one day when I decided to go SS Braided Lines .. This will work for a while with no problems... I ' am trying out some new Track Rod Bars that people tell me are better than stock. Post Pics. later ..
so I'll be using my "" Very Strong S t o c k Trailing Arms "" And They L Q Q K pretty powder coat too Tested strong
Than King Kong Trailing Arms Coming soon to a Garage near me..LOL Stock arms with Rubber Bushings For Now!!! until all the other parts,spacers etc. parts arrive..

Statement
Most Stock Trailing Arms are Rusting from inside out..and made of poor rolled steel..
it is recommended that """ All Opel GT Trailing Arms be Replaced for Safety Reasons""".. Internal Rust.. poor construction Rolled steel
This recommended by the Opel Community

I removed the stock brakes and installed "Big Brakes" on the front

work in progress... I had new Brake Cables custom made for the new rear Disc Brakes. Made to center tensioner using 8mm threaded machine screw

I also finished up the new Trailing Arms ( Links ) Mod. took a bit of time to order the right size material and accurately measure and cut the spacers and shims...painted to prevent rust

I Greased the ball end with Marine anti-corrision ( water proof grease..like marine trailer bearing grease) to prevent rust.

I made brake cable bracket using split ring collars, one on the trailing arm and a 10mm on the cable drilled and tap using harden 8/32 set machine screw as fastener until I can tac weld

The main thing isto make sure the cables don't Rub touch the rotors or the back of the wheels

I also installed a new 2" German Exhaust ,,,while the rear end was out.. I'll post photo's soon

Next is to install new MC and Booster with Proportioning Valve and new Chrome Brake Support Rail...

Here is the Installed "" New German Exhaust System"" 2 inch Dia. pipe is a "" Perfect Fit""

with Large Oval Rear S.S. Pipes makes a deep throaty Sound.. not too loud either "Nice Job"

Work in progress is getting old MC and booster removed ..Paint that area yellow again as it was hidden w/ mc booster unit. Install the New Parts .. I'll post some more photo's of that chapter of the project..stay tuned

Quote from Norbert

Mike

Exhaust sell by German dealer! But made in Sweden by Simons!

Btw. Is first class Exhaust with a real deep sonor sound out of Sweden Steel!

The sound from the S.S. Oval Rear Pipes sounds "" Sonor"" OK ( It was worth waiting for Exhaust to arrive and costs $$ ) You can't get this kind of quality and craftsmanship here done like this on a Opel GT in USA ..sorry Sweden Steel and by Simons Five Stars ( Thumbs Up )

I've have started to install the new Larger Master Cylinder and Larger Power Booster units. After taking a Good look at the work. I thought it Best to Remove the Brake parts and Freshen Up the Yellow Paint behind ( Inner Fenders in frontend body man thought it best to paint under coat black some 20 years ago) Cleaned with Liquor Thinners meesy job

"" I thought it was going to be tough removing the MC and Booster unit's Out but,,,, had just enough hood hinge clearance""

"" Not sure parts about going back "" can't raise hood 100% on my Lifting system and ceiling Height""

I made a Side Flask using a Mason Jar and using a Vacuum pump to remove Brake fluid from Reservoir and aid in brake bleeding later

Then more cleaning and sanding,, I Have a small amount of matching paint to Mix/ match/ To make for a Nice Job  

Here are some photo's of the paint work then back to the Brake work...

More Photo's Work in Progress .. The Hood Hinge Might be a issue for the new power booster unit ...will see.. really don't want to remove the hood.... or lower car off lift.. yuk

Back to the Paint work ...

""" Now That's Matching Citrus Yellow Bird Paint """"

Fresh Paint

Booster is ready/// notice other half Black .. job for another day ..couple drips not too bad Now to Get this Darn Booster to fit and up into place ..... Sleep Lots of masking tape to protect wires from paint

Now One Half of the GT Engine Bay / Compartment is Painted Citrus Yellow. Matching Paint.. Original Paint Chrome Yellow ""LQQKS GOOD to me""