Well, 3 months, ~$300 worth of beer, and ~ $450 worth of miscellaneous parts later; Frauline Frankenbenz 240D moved out of the garage under her own power. Here's the skinny on everything we did:

1) removed the completely blown 4 cyl engine
2) removed the completely good 4 sp manual transmission
3) replaced the engine with a good 5 cyl turbodiesel from an 84 300SD
4) hooked the good 4sp manual behind the 5 cyl turbodiesel
5) shortened the front driveshaft by 10.65 cm, shortened the shift linkages to fit
6) put a 2.88 rear diff from an 85 SD on the rear end.
7) shortened the 84 SD exhaust to fit under the 123 body, and did alot of welding to get exhaust hanging points.
8) cursed alot
9) hybridized the vacuum and electrical systems as best as possible
10 cursed alot more
11) new shocks all around

note: between all steps, insert "drank beer"

We've done some test driving, and amazingly it all works. 1st gear sucks, even though one can get the tires to squeal on a takeoff! Everything else is very peppy. Turbo spools up nicely at higher speeds. Ride issues were solved with new shocks. Two big issues: 1) can not get the tranny into Reverse (yes I pulled up!) if it gets close to being in reverse, then it gets all jammed up and I cant get it out again without getting under the car and fiddling with the linkages up by the gear shift lever. (note: this did not happen before the swap) 2) Engine vibration at all speeds, more noticeable @ low. We did not put add'l engine shocks on, so that may be the issue. We took it to our friendly Bosnian mechanics to diagnose. They agreed that it probably was extra engine vibration that was causing what we felt and would figure a way to dampen it. Any ideas on the linkage issue? Anyone...... Anyone? Thanks for all your help. We never would have been able to do it without this resource!

Seems that if the tranny shifted and operated properly only prior to the swap, it would be reasonable to assume that the tranny didn't just decide to loose reverse during the removal and installation into the 240.......soooo my bet would be that there is a linkage issue you have yet to resolve!

Although, there is Murphy's law, but IIIIIII, doubt it!!!!

Did you shorten the linkages by exactly 4 inches ?

And of course you'll be posting the many pictures you took shortly - right?

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Peach Parts W124.128 User Group.

80 280SL
85 300SD
87 300TD
92 300D 2.5 Turbo
92 300TE 4Matic

now 4" further back...is the linkage fouling on the tunnel? check carefully and you may have to bend something a little to get clearance.

great job!

tom w

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[SIGPIC] Diesel loving autocrossing grandpa Architect. 08 Dodge 3/4 ton with Cummins & six speed; I have had about 35 benzes. I have a 39 Studebaker Coupe Express pickup in which I have had installed a 617 turbo and a five speed manual.[SIGPIC]

..I also have a 427 Cobra replica with an aluminum chassis.

we were binding up... under the gear shift...

So, when watching someone shift through the gears from under the car, for some reason the reverse lever coming down from the gear shift above will bind on the 1-2 lever, but only when the linkage rod is there. I've adjusted the angle of the screw-on eye+grommet of the reverse linkage rod, and tried bending it - but I can't figure out why (even without the clip installed under the gearshifter) it pulls the reverse lever into thinking its 1st and gets stuck. That's what appears to be happening. Is this a spring issue in the gear shift mechanism above the linkages maybe? Maybe I just need to bend that rod way out to provide clearance b/t the two... I'll let you know if we figure it out. Meanwhile, we'll just have to be strategic about parking....haha. Any other suggestions about that mechanism are appreciated. Thanks!

Pictures of a very hoopty hybridization will come shortly, after the Bosnian Brothers have figured out engine shocks. Lets just say, velcro ties and electrical tape have become my very good friend...

After the transplant did you adjust the ALDA to near full out? THis adjustment usually improves pick-up before the |Turbo spools up...

what an amazing project!!!

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PagodaLOVER
1967 230SL, manual
1959 180D, manual

What made you want to do this conversion rather than just buying a turbo diesel and repairing the 240 or selling the body?

__________________
"I would rather be ashes than dust!
I would rather that my spark should burn out in a brillaint blaze
than it should be stifled by dryrot.
I would rather be a superb meteor,
every atom of me in magnificent glow,
than a sleepy and permanent planet.
The proper function of man is to live, not to exist.
I shall not waste my days in trying to prolong them.
I shall use my time."

-Jack London 1876-1916

1983 300CDT (running WVO since 12/05)
1981 300SD (parts car)

The man had a lot of spare time on his hands.....

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Proud owner of ....
1971 280SE W108
1979 300SD W116
1983 300D W123
1975 Ironhead Sportster chopper
1987 GMC 3/4 ton 4X4 Diesel
1989 Honda Civic (Heavily modified)
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Section 609 MVAC Certified
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"He who fights with monsters might take care lest he thereby become a monster. And if you gaze for long into an abyss, the abyss gazes also into you." - Friedrich Nietzsche

that you have the shift rod in backwards?

tom w

__________________
[SIGPIC] Diesel loving autocrossing grandpa Architect. 08 Dodge 3/4 ton with Cummins & six speed; I have had about 35 benzes. I have a 39 Studebaker Coupe Express pickup in which I have had installed a 617 turbo and a five speed manual.[SIGPIC]

..I also have a 427 Cobra replica with an aluminum chassis.

About the vibration... did you get the flywheel (un)balanced to match the out-of-balance of the flexplate? Flywheels are normally zero-balanced, but I have read that OM617 ones are deliberately out of whack in order to externally balance the crankshaft...

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Currently converting a 1984 Toyota Land Cruiser FJ60 to use a 1985 300D engine and tranny... Engine/tranny are in, no transfer case or wiring yet.

question.

we have been around the block on this one.

according to the manual posted on skinner box (i think), the 615 and 616 flywheels are balanced with the crank. first hand experience seems to contradict that, but that is what the manual says.

on the 617, the manual says that the entire engine is balanced on a machine. it does not mention the flywheel or flex plate. in my personal experience, it certainly appears that the 617 flywheel is neutrally balanced. i put a automatic crank into a stick na 617 with no possibility of any special balancing with the flex plate and the car is smooth as silk.

rovermb put a 616 into his rover that was originally automatic and put a flywheel behind it with no ill effect.

but still the manual does say it is balanced with the crank. and shows how to transfer the balance to another flywheel. i dont know if it will work to transfer the balance from a flex plate to a flywheel or not.

i have sent my spare 240 flywheel to the shop to be checked for neutral balance. it is off the engine and has no indexing marks so if it was specially balance it is lost. i am planning to use it on a 617 so i will have it neutrally balanced if it is not already.

hope this helps. good luck on your project.

tom w

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[SIGPIC] Diesel loving autocrossing grandpa Architect. 08 Dodge 3/4 ton with Cummins & six speed; I have had about 35 benzes. I have a 39 Studebaker Coupe Express pickup in which I have had installed a 617 turbo and a five speed manual.[SIGPIC]

..I also have a 427 Cobra replica with an aluminum chassis.

a 240 to 617 power.

the 240 is lighter, simpler to work on and has manual ac controls instead of the dreaded automatic ones.

then you have the best of both worlds, simplicity to maintain and max diesel performance.

tom w

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[SIGPIC] Diesel loving autocrossing grandpa Architect. 08 Dodge 3/4 ton with Cummins & six speed; I have had about 35 benzes. I have a 39 Studebaker Coupe Express pickup in which I have had installed a 617 turbo and a five speed manual.[SIGPIC]

..I also have a 427 Cobra replica with an aluminum chassis.

...and alot of beer.