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I just finished a 1000 mile road trip with this car and realized I needed to update this thread.
The most important thing I learned in this project is that the throwout bearing for the early and late transmissions on the 240 are NOT interchangeable.
When reassembling, I gathered all the clutch parts I had and picked the best of the bunch to install. I didn't realize that the fingers that touch the clutch forks are not in the same location on the early and late throwout bearings. I put an early bearing in a late transmission.
The install went fine, but when I fired it up the first time and put it in gear the car would not move. I could hear the clutch disc touching the flywheel, but the incorrect throwout bearing was keeping the pressure plate from fully pressing the clutch against the flywheel.
There is nothing worse than installing an engine in the morning and having to drop the transmission in the same car that afternoon.
After that screwup, things went pretty smoothly. I changed all the orings in the AC system before charging it and recommend that everyone do that in these systems. Several of the orings were likely original and were in terrible shape.
Before taking off on this road trip, I had run 3 tanks of fuel through it to make sure it was roadworthy.
The car runs great and has good power. I cruised at 75 mph for hours at a time last week and it would cruise at 80, but it was loud. You really need a different rear end or a 300D to maintain speeds that fast for long. Trip average fuel economy was 29.6mpg.
I think I need to clean or change my oil separator. Cruising around town the motor burned no oil, but on the highway I burned almost a quart between fillips. I need to do some more research, but blowby is minimal so I don't think its a worn engine, particularly since it doesn't burn oil running around town.
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1985 300 TD 448K
1984 300 TD 278K
1983 240D euro 240k
1994 f-250 idi turbo 330K
1986 f-350 IDI
1987 F-350 IDI
1985 JD 1050 4wd
1965 IH 3660
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