616 to 617 swap - PeachParts Mercedes-Benz Forum

CannonBall · #1 05-30-2005, 12:25 PM

Ok, I've searched but I'm trying to get everything down here.

Where I stand right now the 616 and manual are out of my 123.
I need a car as long as possible for parts runs and such so I'm not pulling the 617 from the 116 until I absolutely have to, probably tomorrow or Wednesday (pending what goes on today.)

Ok so lets go over parts first:
Clutch Disk – I2010-12397 (these are the numbers under the picture, if they’re wrong and I’m an idiot please point me in the write direction.)
Pressure Plate - I2000-12245
Pilot Bearing – SFK 6202
Release Bearing – This one has 2 PN’s not sure which one I need there is I2020-95249 and 11978 for 219674 and 219675 respectively. Anyone know which one I need or do I have to look at my VIN? The car isn’t at my house so that’s kind of a pain.

Case Bearing – J2021-24297
I’m assuming this is the bearing at the base of the input shaft on the tranny. I’m pretty sure mine is no good, it has lots of play. If this is incorrect please let me know.

I should also be changing the front and back seals on the tranny. I see in the online parts catalogue Output shaft seal, but no input. Any help here? I’d like to order all the parts today.

What I have left to do after I have all the parts. Get the flywheel off the auto and match my 616 manual flywheel to that. Get the drive shaft shortened and rebalanced. And get my shifter linkage the proper length (I will do this once the tranny is in, I’ve been told that is the easiest way.) I can put the pilot bearing in the 617 with it out and once the flywheel is back I can install all of the clutch parts attach the tranny and drop the engine/tranny combo in. Does the x-member for the tranny have to be modified or will it go into the holes that are already on the frame as long as I move the tabs? Lets see… should the water pump and all of those gadgets work from the 116 to mine, or should I be swapping parts over while the engine is out and I’m waiting for flywheel balancing and hot drive shaft action. Umm ok, my brain is now fried. More to come! Thanks everyone.
-Nate

t walgamuth · #2 05-30-2005, 12:31 PM

prob can relocate existing cross member. dont forget that the 617 has a larger radiator. didnt mention years so if your car has the york ac there is an adaptor available from "vinntage air" whick allows use of a modern japanese ac compressor. the your is incompatable with modern ac freon. good luck. also should change rear diff and speedo. for best results.

t walgamuth · #3 05-30-2005, 12:32 PM

also if your car has automatic glow plugs you will need to change the relay to a 5 cyl type.

CannonBall · #4 05-30-2005, 02:30 PM

yeah I have the whole spare car, so I have the glowplug relay. The diff is not interchangable and the speedo is in km/h so no go. Thanks though.

Can anyone confirm the parts I wasn't sure of?
-Nate

Johnhef · #5 05-30-2005, 03:32 PM

I did a similar swap last year, but the other way around, 617 to 616.

from what I recall, the driveshaft was different, and the trans crossmember had to be moved forward but there are already holes in the underbody to slide the nuts into. Everything else was fairly easy to overcome except for the linkage, which took some thinking to figure out how to make the new style engine work with the older style car. Glow system rewiring was fairly easy too.

t walgamuth · #6 05-30-2005, 03:33 PM

are you sure the diff wont work.? i would bet it would.

CannonBall · #7 05-30-2005, 04:14 PM

Yeah, if it were a 123 and/or (not sure if a later model SD rear end would work) not an SD it would work. It's not the same rear end. I am having the DS shortened 4"
-Nate

Johnhef · #8 05-30-2005, 06:47 PM

try swapping just the front half of the driveshaft, thats what I did... but then again, both of the cars i did were 123's

t walgamuth · #9 05-30-2005, 07:09 PM

i got a diff from "the benz store" in ky or tn. got it out of hemmings i think. about $200. also have speedos reasonable.

Johnhef · #10 05-30-2005, 10:42 PM

i think theyre in georgia, but yeah, I got my speedo from them too.

Old300D · #11 05-30-2005, 11:02 PM

As I recall I had to use a different crossmember to move the transmission back. I believe the transmission tunnel narrows, and although there are holes, the 616 crossmember is wider. So you need a 617 crossmember. I reserve the right to be wrong though, and it's easily verified if you can get underneath and measure.

CannonBall · #12 05-31-2005, 12:15 AM

Quote:

Originally Posted by Old300D

As I recall I had to use a different crossmember to move the transmission back. I believe the transmission tunnel narrows, and although there are holes, the 616 crossmember is wider. So you need a 617 crossmember. I reserve the right to be wrong though, and it's easily verified if you can get underneath and measure.

Yeah, this was kind of what I was getting at. Just eyeballing it (perhaps the most scientific method at my disposal) it would appear that the "frame" narrows. I'll just swap the x-member off the 617 auto or if it comes to it bust out the trusty welder. Thanks.
-Nate

t walgamuth · #13 05-31-2005, 10:10 AM

yes the frame narrows. so it must be either slotted holes in the crossmember or different crossmembers, cant remember... think its different crossmembers.

Johnhef · #14 05-31-2005, 07:48 PM

its different crossmembers, I remember that now.

CannonBall · #15 06-01-2005, 10:42 AM

ok, parts ordered. I ordered both release bearings and I'll just return the wrong one. My vin is wack and didn't match either of the ones. My release bearing is in great shape anyway. I also didn't order the seals because they didn't have them or the "case bearing" because the guy didn't know if that was the right part or not. They should get here by saturday, and hopefully by then I can have the DS and flywheels done and have everything ready to go in. Thanks for your help folks.
-Nate

Similar Threads
Thread	Thread Starter	Forum	Replies	Last Post
swap from 617 to 603?	hotskillet	Diesel Discussion	29	07-26-2005 02:28 PM
Injector (617) vs Injector (616)	coachgeo	Diesel Discussion	7	05-25-2005 10:33 AM
Swap TD, 617 for tranny	Stevo	Mercedes-Benz Used Parts For Sale & Wanted	0	04-17-2005 10:54 AM
What can you swap a 617 turbo into?	JHZR2	Diesel Discussion	6	12-11-2004 10:51 PM
617 Swap	paulem	Diesel Discussion	0	01-07-2004 03:24 PM