What model of the gearbox is fitted? 717.XXX?

Only noise under load?
No vibrations?

Thank you for your assistance!

__________________
You can't always get what you want, but if you try sometime you just might find you get what you need.

With a 2.5 non-turbo in the snowless south the question begs why? You're not going to have trouble spinning tires.

__________________
You can't always get what you want, but if you try sometime you just might find you get what you need.

I attempted switching a 165mm diff from an '84 2.3 in place of the 185mm diff in the '87 2.5dt. The 185mm have a larger diameter axle and as a result a larger axle shaft. The axle shaft from the 185mm is apx 1.25" in diameter whereas the 165mm axle shaft is apx 1" in dia so they won't exchange. So, you have to use the axles that fit the 165mm axle shafts which means you also have to swap out parts on the hub ends so those axles will fit.

If you have a 185mm diff and want to utilize a 165mm diff, then I found it easier to swap over the entire subframe.

__________________
You can't always get what you want, but if you try sometime you just might find you get what you need.

I don't have the gearbox numbers handy, but it was harvested from an '84 2.3l gasser.

Yes, noise is only under load at between around 1400 -1900 rpms in 3rd and 4th gears only.

There is no obvious vibration that I can feel. One of my sons has been driving the car for a while but he has returned to school and I'm going to start using it as my DD so I will be able to begin trying some things to identify the source.

I thought the earlier suggestioin of bushings on the middle shifter rod were a logical place to start. We did not replace those bushings during the tranny swap and I don't recall them being in great shape.

Where would you start looking?

__________________
You can't always get what you want, but if you try sometime you just might find you get what you need.

Walkenvol,
Sir, #107 is the axle flange.


and #5 is the axle shaft

OK, here is distinction of the 165 and 185 mm diffs:

• different rear cover - for 201, for 124
• different axle flanges
• different propeller shaft flange

In case of swap 165 to 185 or 185 to 165, it needs:
diff
axle shafts
flange of propeller shaft from "old" diff

Bushings.

Sorry if my post was unclear as I was attempting to describe what we did and accidently called the axle flange an axle shaft.

The bottom line to me is the 185mm diff is beefier than the 165mm including everything that attaches to it; drive shaft, axle flanges and axles. I did not compare the hubs as once I understood the axles would need to be swapped it became apparant swapping the entire subframe would be less work to get it rolling until I could locate a 185mm diff with the desired gearing.

Thanks to your help and others, it appears I've found what I need and will get about returning the original beefier subframe componets.

__________________
You can't always get what you want, but if you try sometime you just might find you get what you need.

Shifter bushings as discussed earlier?

__________________
You can't always get what you want, but if you try sometime you just might find you get what you need.

I mean all bushings, rubber parts, etc.
But shifter bushings... Hm, maybe it will help.

Sweet. Would you know if the W202's would fit? Some places advertise W202 rear diffs with a W124 parts number

__________________
Current: 1975 450SEL, 83 300D, 88 Yugo GVX, 90 300D OM603 swap, 91 F150 4.6 4v swap, 93 190E Sportline LE 3.0L M104 swap, 93 190E Sportline LE Megasquirt, 03 Sprinter, 06 E500 4Matic wagon.

I agree. After doing some research, it will be too much trouble. I still plan on doing a brake upgrade on my car, probably the 400E and I wanted to use the master cylinder and brake booster out of my parts car but its ABS unfortunately. My master cylinder is on its way out, so it begs the question, can I use a W201 non-ABS master cylinder in the 2.6's brake booster? It is a bigger and better booster than the one I have, would work better with the 400E brakes than my current one. 400E brakes may seem a bit overkill but even with a functioning master cylinder, the stopping distances on a 190D 2.5 are abysmal, somewhere around 150ft if I recall correctly. I have wider tires on the 16 inch E class rims installed by the PO which adds unsprung weight but also bigger contact patch when I have functioning brakes again.

__________________
Current: 1975 450SEL, 83 300D, 88 Yugo GVX, 90 300D OM603 swap, 91 F150 4.6 4v swap, 93 190E Sportline LE 3.0L M104 swap, 93 190E Sportline LE Megasquirt, 03 Sprinter, 06 E500 4Matic wagon.

As I know, the 202's diff will fit.
But only standard diff without ETS/ASD (housing p/n 124 351 06 05).
C 220 (202.022) - 3,07
C 230 (202.023) - 3,27
C 230 (202.024) - 3.46
C 280 (202.028) - 2.87/3.07

Yes, you can use ABS or non-ABS master cylinder with 2.6's booster, but with 2.6's booster possible to use only master cylinder from 124 (any, except 400/500 and E-class), 201.029 (2.6), 201.034 (2.3-16) or 201.035 (2.5-16) - 2.6 has booster with a double diaphragm.
Also you can use (better if you use ) master cylinder + booster from 400 E. It's possible to fit.