I'm at a crossroad and could use some seasoned advice. This weekend I attempeted to replace the vacuum modulator on the transmission of my 300D. That allen screw is really hard to access. Really hard (too hard) to break loose. No room to apply heat or strike to break loose. Ultimately I stripped the head of the screw. Tried to use EZ out, but the area is so tight I had no luck. My question is what should I do next? I've considered lowering the transmission for better access. Too, I've considered cutting a hole in the center tunell for better access. I think the first thing I should do is ask someone who knows more than me. Anyone else been where I am?

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John Schroader
bio burnin' 83 300D, '83 300 SD, '79 240D
"I've never met a man who was good at making excuses who was good at anything else" Ben Franklin
"You cannot permanently help a man by doing for him what he could and should do for himself" Abraham Lincoln

Can you get a dremel in there and just cut off the head? Or is the head recessed?

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http://superturbodiesel.com/images/sig.04.10.jpg
1995 E420 Schwarz
1995 E300 Weiss
#1987 300D Sturmmachine
#1991 300D Nearly Perfect
#1994 E320 Cabriolet
#1995 E320 Touring
#1985 300D Sedan
OBK #42

Yep it is very tight in that area. The best thing to do is to drop the transmission by removing the 4 bolts on the mount and the 2 bolts on the center drive shaft bearing. You can slowly lower down the tranny by using a jack with a block of wood between the two. There is a point when you lower it down the tranny will just hang there.

As far as your bolt is concerned, try the EZ-out again. If it doesn't work and the bolt is not flush, this works great.

http://www.sears.com/sr/javasr/product.do?cat=Hand+Tools%2C+General+Purpose&pid=00952162000&vertical=TOOL&subcat=Bolt-Out%2C+Taps+%26+Dies&BV_UseBVCookie=Yes

BTW-what size hex wrench were you using?

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1983 123.133 California
- GreaseCar Veg System

Thanks for the help. Cannot get a dremmel in there with the transmission in place. Can't get much of anything in there. As for the size of the allen -- I used a 5mm. Looked it up on Alldata and that was not the recommended size but 4 was too small and 6 was too large. Fitted it in as snugly as possible, but got sorry results. I will try lowering the trans. Just a little nervous about putting something very expensive in a bind.

__________________
John Schroader
bio burnin' 83 300D, '83 300 SD, '79 240D
"I've never met a man who was good at making excuses who was good at anything else" Ben Franklin
"You cannot permanently help a man by doing for him what he could and should do for himself" Abraham Lincoln

Checked out the sears website. I did, in fact, try one of these (thanks to my tool rich buddy) but there was not room to get a socket on it. Probably will work once I lower the transmission.

__________________
John Schroader
bio burnin' 83 300D, '83 300 SD, '79 240D
"I've never met a man who was good at making excuses who was good at anything else" Ben Franklin
"You cannot permanently help a man by doing for him what he could and should do for himself" Abraham Lincoln

Lowering won't help you as much as you think. The 300 valve cover hits the firewall before the modulator gets below the tunnel level. Also beware of the fan catching on the shroud and breaking it. Ask me how I know.

It took me 5 trys to get that modulator to seal properly, then I replaced the whole trans due to a chunk of cement taking out the valve body.

__________________
Adam Lumsden
(83) 300D
Vice-President of the MBCA International Stars Section

Any thoughts or warning about carefully drilling through the tunnel with a 3" hole saw?

__________________
John Schroader
bio burnin' 83 300D, '83 300 SD, '79 240D
"I've never met a man who was good at making excuses who was good at anything else" Ben Franklin
"You cannot permanently help a man by doing for him what he could and should do for himself" Abraham Lincoln