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  #1  
Old 12-27-2006, 08:03 PM
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How to replace a clutch in a 240D - Pictorial

I replaced the clutch in my 240 and took some pictures along the way. The following is not designed to be a step by step guide, but rather to highlight some of the main points and hopefully give someone confidence to do the job themselves who is debating whether or not to perform this task. It is fairly straightforward but does require some mechanical skills as you will have to do some "figuring" to get everything right. The whole job took me about 6.5 -7 hours though I didn't do it all in one sitting. I've never changed a clutch before so maybe others can do it much faster. Just be patient and give yourself plenty of time and you should have no problems.

1. The first thing is to disconnect everything from the tranny - slave cylinder, speedo cable, shift linkage, etc.

2. Mark the position of the drive shaft to the flex disc. I used leftover paint I had from painting my gauges See Pic 1.

3. Remove the cross bar supporting the bottom of the tranny. Here you see the tranny mount exposed. See Pic 2.

4. This is the cross bar removed. See Pic 3.

5. Remove the bolts holding the driveshaft to the flex disc. See Pic 4.

Attached Thumbnails
How to replace a clutch in a 240D - Pictorial-clutch1.jpg   How to replace a clutch in a 240D - Pictorial-clutch2.jpg   How to replace a clutch in a 240D - Pictorial-clutch3.jpg   How to replace a clutch in a 240D - Pictorial-clutch4.jpg  
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Scott
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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  #2  
Old 12-27-2006, 08:09 PM
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6. Pry the drive shaft back from the flex disc using a screw driver. It simply retracts back. See Pic 5.

7. Remove the other support bracket which is also attached to your exhaust pipe. See Pic 6.

8. Unbolt your transmission bolts. Don't forget the starter bolts too. Remove the tranny. See Pic 7.

9. This is what it looks like with the tranny removed. You are looking at the old clutch. See Pic 8.
Attached Thumbnails
How to replace a clutch in a 240D - Pictorial-clutch5.jpg   How to replace a clutch in a 240D - Pictorial-clutch6.jpg   How to replace a clutch in a 240D - Pictorial-clutch7.jpg   How to replace a clutch in a 240D - Pictorial-clutch8.jpg  
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Scott
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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  #3  
Old 12-27-2006, 08:14 PM
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I had not done other clutch jobs before doing my MB either but others have said its relatively easy as far as clutches go. I leave the cross member tranny support on the tranny and just let the two 17mm bolts go. Also its a good idea to mark both halves of the drive shaft just in case it comes adrift Your time was better than the first one I did.
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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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  #4  
Old 12-27-2006, 08:18 PM
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10. Note the release bearing on the input shaft with the fork behind it. See Pic 9.

11. I went ahead and removed the flywheel. Note that I have already removed the pressure plate and clutch disc. Removing the flywheel is probably not necessary for removing the pilot bearing but I did anyhow. If you remove the flywheel, mark its position just like you did the driveshaft. Clean the flywheel with some sandpaper and then brake or carb cleaner. Don't clean off the mark you made with the cleaner . Note the pilot bearing sits inside part of the crank. See Pic 10.

12. You will need to put a 27mm socket on your crank pulley with a long extension that hits the floor to keep the engine from turning while you are loosening bolts on the flywheel or pressure plate. See Pic 11.

13. You will need to rent a pilot bearing removal tool. I got mine at Autozone. You will also need to rent a slide hammer which attaches to the end of the tool. Note that the pilot bearing has a cover on it which will be removed first. See Pic 12.
Attached Thumbnails
How to replace a clutch in a 240D - Pictorial-clutch9.jpg   How to replace a clutch in a 240D - Pictorial-clutch10.jpg   How to replace a clutch in a 240D - Pictorial-clutch11.jpg   How to replace a clutch in a 240D - Pictorial-clutch12.jpg  
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Scott
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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  #5  
Old 12-27-2006, 08:24 PM
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14. This is the pilot bearing cap removed and still on the end of the tool. See Pic 13.

15. This is the pilot bearing still in place. My tool was too small to squeeze through the hole in the pilot bearing. I ended up using two coat hangers that I normally use for removing the instrument cluster to fit behind it and yank it out. Its in there TIGHT. See Pic 14.


Installation is reverse of removal. Make sure you have the proper clutch alignment tool for centering the clutch disc. The Haynes manual gives you the torque values and some other good info. I also went ahead and replaced the slave cylinder. I didn't even have to bleed it. Brake fluid just started pouring in and that was that. Don't ask me why or how because I don't understand it but its working just fine.

If any more experienced board members have helpful comments, please feel free to add them. I would like this post to be the one people can use if they decide to replace their clutch.

Good luck,

Scott
Attached Thumbnails
How to replace a clutch in a 240D - Pictorial-clutch13.jpg   How to replace a clutch in a 240D - Pictorial-clutch14.jpg  
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Scott
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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  #6  
Old 12-27-2006, 08:29 PM
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Great post, isn't this my posting technique??

I feel a new "DIY Article" coming on.

Dave
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1970 220D, owned 1980-1990
1980 240D, owned 1990-1992
1982 300TD, owned 1992-1993
1986 300SDL, owned 1993-2004
1999 E300, owned 1999-2003
1982 300TD, 213,880mi, owned since Nov 18, 1991- Aug 4, 2010 SOLD
1988 560SL, 100,000mi, owned since 1995
1965 Mustang Fastback Mileage Unknown(My sons)
1983 240D, 176,000mi (My daughers) owned since 2004
2007 Honda Accord EX-L I4 auto, the new daily driver
1985 300D 264,000mi Son's new daily driver.(sold)
2008 Hyundai Tiberon. Daughters new car
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  #7  
Old 12-27-2006, 08:29 PM
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Is the pilot bearing solid or a roller bearing. If its solid you can use grease to remove it. Pack the center hole of the bearing with grease, Find a solid shaft or pin that fits snugly into the pilot and smack it with a hammer. The grease will hydraulically push the bearing out. I've done this hundreds of times.
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  #8  
Old 12-27-2006, 11:37 PM
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Quote:
Originally Posted by Scott98 View Post
11. I went ahead and removed the flywheel. Note that I have already removed the pressure plate and clutch disc. Removing the flywheel is probably not necessary for removing the pilot bearing but I did anyhow. If you remove the flywheel, mark its position just like you did the driveshaft. Clean the flywheel with some sandpaper and then brake or carb cleaner. Don't clean off the mark you made with the cleaner . Note the pilot bearing sits inside part of the crank. See Pic 10.
The flywheel should be resurfaced by a machine shop whenever you install a new clutch. Any surface irregularities will significantly hurt the new clutches life. It only costs $30 and takes less than an hour to get a flywheel resurfaced. A new pressure plate should also always be used with a new clutch disk.
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  #9  
Old 12-28-2006, 11:05 AM
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I have done two clutches. FWD Accord and RWD 200SX. RWD is much easier IMO. And these MBs have tons more clearance for wrenches than my 200SX. The Accord was a complete failure all my fault. I somehow managed to drop a nut in the opening where the starter goes. On the initial test drive it came out, popped a .25 sized hole in the tranny case and dumped all the gear oil... Thats ok because the 5th gear synchro was going out anyways .
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1987 300D Sturmmachine
1991 300D Nearly Perfect
1994 E320 Cabriolet
1995 E320 Touring
2001 Eurovan FOR SALE
1985 300D car, sold and missed.
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  #10  
Old 12-28-2006, 12:12 PM
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great thread

Based on my review of a voluminous number of maintainence receipts, I believe I am on my original clutch. I'm sitting at 267,000 miles now. After reviewing the haynes manual and your post I'll likely do this job myself. Thanks for sharing.

Kevin
1979 240D manual
1984 190D manual
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  #11  
Old 12-28-2006, 07:34 PM
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Quote:
Originally Posted by yellowbenz View Post
After reviewing the haynes manual and your post I'll likely do this job myself. Thanks for sharing.

Kevin
1979 240D manual
1984 190D manual
Glad to hear. That was my main reason for doing this pictorial. I read a lot about it on this forum before deciding to attempt it myself but I think a picture speaks a thousand words.

Scott
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Scott
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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  #12  
Old 12-28-2006, 08:56 PM
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Nice job. I guess my first post got in there before your third one, sorry didn't mean to interrupt you. Yah, I always paid someone else to put clutches in cars but, no more, I have now fabricated a cradle for a floor jack which is my MB tranny jack.
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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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  #13  
Old 12-28-2006, 09:33 PM
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Quote:
Originally Posted by Stevo View Post
Nice job. I guess my first post got in there before your third one, sorry didn't mean to interrupt you. Yah, I always paid someone else to put clutches in cars but, no more, I have now fabricated a cradle for a floor jack which is my MB tranny jack.
No problem. The tranny is light enough that you can pull it out without a tranny jack if you wanted to. I would estimate its weight at around 50 - 60 pounds.

Scott
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Scott
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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  #14  
Old 12-28-2006, 10:15 PM
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Quote:
Originally Posted by Scott98 View Post
No problem. The tranny is light enough that you can pull it out without a tranny jack if you wanted to. I would estimate its weight at around 50 - 60 pounds.

Scott
I borrowed one for the first couple I did. I think I wouldn't want to do the job without one, I get sore just thinking about 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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  #15  
Old 01-27-2007, 01:47 PM
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i recently did this also but i broke a flywheel bolt off into the crank (DUMBASS MOVE!) well i had no other way to get a bolt of the same length because the bolts that came off of the 240d was an automatic so the bolts were longer so i deceded i could cut a bolt and put a washer on it and we tourqed it and it works fine.i swear to god though i thought i was gona kill myself when i saw that bolt break off. turned out i did a smart thing i lubed up the holes with synthetic to make them easier to come out. and the stub that was sticking out came out like butter.

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