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  #1  
Old 08-31-2006, 08:20 PM
biobenz240d's Avatar
WNY Biodiesel Coop
 
Join Date: Jun 2006
Location: Western New York
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replacing clutch '83 240D

Hi, next week I will be replacing the clutch on my 83 240D. The release bearing is starting to make some noise , so after 258K mi. I think its about time for the works .(disc,pressure plate,release bearing ,pilot bearing) I have replaced clutches on various cars and trucks ,but not on a Benz. What I would like to know is there any tricks or anything out of the ordinary that I need to know? Better to ask first and feed off the vast knowledge of this forum than to make the job harder than it is . thanks in advance.

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'83 240D 264k on 100% biodiesel/ 31mpg
83 300D 217K the $800 gem
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  #2  
Old 08-31-2006, 09:40 PM
Waitn For The Bus All Day
 
Join Date: Jul 2004
Location: south east pa.
Posts: 1,786
I hope someone replies. I'll be changing mine soon too. Same type symptoms.

I know a local guy that has 420K on his original clutch.

Cheers,

Bill
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  #3  
Old 08-31-2006, 09:46 PM
Scott98's Avatar
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Location: Weston, FL
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I just bought a 240 4 speed. I hope someone replies too because I plan on printing off this thread and saving it just in case...

Scott
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1982 Mercedes 240D, 4 speed, 275,000
1988 Porsche 944 Turbo S (70,000)
1987 Porsche 911 Coupe 109,000 (sold)
1998 Mercedes E300 TurboDiesel 147,000 (sold)
1985 Mercedes 300D 227,000 (totaled by inattentive driver with no insurance!)
1997 Mercedes E300 Diesel 236,000 (sold)
1995 Ducati 900SS (sold)
1987 VW Jetta GLI 157,000 (sold)
1986 Camaro 125,000 (sold - P.O.S.)
1977 Corvette L82 125,000 (sold)
1965 Pontiac GTO 15,000 restored (sold)
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  #4  
Old 08-31-2006, 09:56 PM
Stevo's Avatar
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One thing that I did last time that saved time later was too remove the clutch slave from the bell housing that will save you from bleeding the system, I used to disconnect the hydraulic line, easier at the time but more work later. Removing the linkage "clips" was a challenge the first time. Also be sure and mark the drive shaft in case its gets seperated, which can happen. Doing the clutch on these cars is not bad at all and feels so good when you drive it
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1985 Euro 240D 5 spd 140K
1979 240D 5 spd, 40K on engine rebuild
1994 Dodge/Cummins, 5 spd, 121K
1964 Allice Chalmers D15 tractor
2014 Kubota L3800 tractor
1964 VW bug

"Lifes too short to drive a boring car"
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  #5  
Old 08-31-2006, 10:28 PM
t walgamuth's Avatar
dieselarchitect
 
Join Date: Apr 2005
Location: Lafayette Indiana
Posts: 38,679
dont forget to have the fw turned smooth. and replace the pilot and throw out bearing while in there and maybe the front seal on the tranny.

but i never would change a clutch just because of a little noise. i would wait til there is a functional problem. it might last a couple ofmore years without doing it.

but if you decide to go ahead, good luck

tom w
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..I also have a 427 Cobra replica with an aluminum chassis.
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  #6  
Old 09-01-2006, 06:57 AM
Admiral-Third World Fleet
 
Join Date: Feb 2002
Location: Central FL
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I haven't installed one yet, but I removed one from a junker and assisted a friend installing one and replaced my slave cylinder. My thoughts are that the mechanical bits are very straightforward. The hydraulics can be fiddly. The area around the slave cylinder is awkward to access and the chances of boogering the hydraulic line are somewhat high. I like Stevo's advice- if you can remove the slave from the bellhousing and keep the hydralics intact, do so. Bleeding can be a pain- bleeding from the right front wheel worked for me.

Rick
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80 300SD (129k mi) 82 240D stick (193k mi)77 240D auto - stick to be (153k mi) 85 380SL (145k mi) 89 BMW 535i 82 Diesel Rabbit Pickup (374k mi) 91 Jetta IDI Diesel (155k mi) 81 VW Rabbit Convertible Diesel 70 Triumph Spitfire Mk III (63kmi)66 Triumph TR4a IRS (90k mi)67 Ford F-100 (??)
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  #7  
Old 09-01-2006, 07:57 AM
t walgamuth's Avatar
dieselarchitect
 
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defiantely avoid breaking the hydraulic clutch system if you can.

they are a royal pain to bleed.

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.
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  #8  
Old 09-01-2006, 12:42 PM
bgkast's Avatar
Rollin' on 16s
 
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I replaced the hydraulic line in my 240 and it bled no problem. When I pulled the engine and transmission I separated the clutch line where the hard line from inside of the car and the line that runs over the tranny connect.
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1982 300SD - 232K miles - Wife's Daily Driver

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  #9  
Old 09-01-2006, 11:34 PM
t walgamuth's Avatar
dieselarchitect
 
Join Date: Apr 2005
Location: Lafayette Indiana
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your clutch master may not have emptied. that is what is tough to get the air out of.

glad you had good luck.

many have not been so lucky.

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.
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  #10  
Old 09-02-2006, 12:07 AM
ForcedInduction
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Bleeding with the caliper didn't work for me. I just bled it like one would a normal brake caliper.

If you can't get an MB alignment tool, one from a mid 90's Chevy S10 works.
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  #11  
Old 09-02-2006, 10:22 AM
Stevo's Avatar
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Quote:
Originally Posted by ForcedInduction View Post
If you can't get an MB alignment tool, one from a mid 90's Chevy S10 works.
I use one from an old (80s) Volvo, same splines.
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1985 Euro 240D 5 spd 140K
1979 240D 5 spd, 40K on engine rebuild
1994 Dodge/Cummins, 5 spd, 121K
1964 Allice Chalmers D15 tractor
2014 Kubota L3800 tractor
1964 VW bug

"Lifes too short to drive a boring car"
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  #12  
Old 09-05-2006, 09:41 PM
biobenz240d's Avatar
WNY Biodiesel Coop
 
Join Date: Jun 2006
Location: Western New York
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The throw out bearing has begun to make noise and is getting louder by the day. I bought my new clutch through Clutch Express in York PA. The kit includes pilot and release bearings , pressure plate ,disc and the clutch alignment tool all for 259$ and no shipping charge . I will get the fly wheel resurfaced and new bolts, I like the idea about not disconnecting the slave cylinder to eliminate having to bleed the system, no need to create a problem. I'll write back aftyer the job is done. Sept. 7 is the day I'll get started but it looks like rain. Driveway mechanic, the garage is full of biodiesel makin' stuff. later
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'83 240D 264k on 100% biodiesel/ 31mpg
83 300D 217K the $800 gem
'82 300D 267K the new WVO project car finished and driving for free
International tractor B275 on B100
Ford 555 backhoe on B100
Sargent 25 ton Rough Terrain crane on B50
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  #13  
Old 09-06-2006, 11:25 PM
t walgamuth's Avatar
dieselarchitect
 
Join Date: Apr 2005
Location: Lafayette Indiana
Posts: 38,679
yep, sounds necessary.

good luck

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.
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  #14  
Old 09-06-2006, 11:40 PM
JimmyL's Avatar
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Quote:
Originally Posted by biobenz240d View Post
I'll write back aftyer the job is done. Sept. 7 is the day I'll get started but it looks like rain.
Do you have the means to take pics during this process? I would love to see this before I ever have to do it. (like I'll ever get a 240D manual..... )
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'85 300TD 235K "The Wagon" Texas Friendly White
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'80 240D 230K "The Squash"
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  #15  
Old 09-07-2006, 03:11 AM
bgkast's Avatar
Rollin' on 16s
 
Join Date: Dec 2005
Location: Vancouver WA
Posts: 6,528
I just did a new clutch when I put the turbo engine in my 240. It is very straight forward, just like any other clutch. I had both the engine and tranny out of the car. I was too cheap to buy an alignment tool, so I very lightly tightened down the pressure plate and used the whole transmission to align the clutch, then pulled the tranny off and tightened down the pressure plate bolts a quarter turn at a time. I disconnected the clutch line at the firewall, but it only took about 10 min to bleed it when I was finished. The PO told me that it the car had had recent clutch work and the throw out bearing looked new so I re-used it and did not have the flywheel resurfaced. I did use some 600 grit emery cloth to rough up the face of the flywheel and pressure plate though. I also put a new pilot bearing in too. Pry off the dust cover, remove the old one, grease the new one, tap it in place and tap the dust cover back on. Itís easy Good Luck.

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1979 240D- 316K miles - VGT Turbo, Intercooler, Stick Shift, Many Other Mods - Daily Driver

1982 300SD - 232K miles - Wife's Daily Driver

1986 560SL - Wife's red speed machine
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