I just ordered this Master rebuild kit which I believe includes friction clutch plates & standard steel plates, paper gaskets, O rings, lip seals, metal clad seals and sealing rings.

What else should I be expecting to replace after 260k miles?

Maybe the bands?

Good luck! Please keep us advised. A pictorial would be very helpful. If nothing else, at least take the pictures for yourself as you tear it down so you can figure out how it goes back together. You may have it apart awhile waiting for parts. I never took my 722.120 apart other than the front pump ( it only had 125K miles when I messed with it), but my wife's 722.315 is on its last legs.


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 (??)

Doh! I think I too have a 722.120 (I guess I forgot, I pulled the transmission and replaced it with a used unit two years ago).

Anyway, I started a blog for this car here and I will definitely post pics.

Yes, you do have a 722.120. I'm not sure what a 722.2 is...

You might look for advice over at the Vintage forum. The four bolt tranny is pretty much a vintage item. Plus there are some pretty saavy people there (not that there aren't here, but there just arene't many of us inclined to tear down a transmission, methinks).

I see you mention Jaggi on your blog- good- you will need him...

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 (??)

Please keep us posted on this, as I plan to do mine latter this year ans up date it with the K1 and B2 kits.

What are the K1 and B2 kits?

Tabor-

I don't think you and I have them in the 722.120. These are in the 722.3xxs.

What's so wrong with your transmission that it needs a rebuild? Symptoms? What was the first sign of failure ?

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 (??)

The front pump seized when it got full of metal shavings. Lots of metal shavings in the pan.

Catastrophic failure

There seem to be a lot of front pump/TC problems with these. Is your TC broken as a result (or as a cause?)?

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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 (??)

My 79 300SD did the same thing! Anyone know what causes it? I just replaced the TC and pump, I'm afraid it will happen again.

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1983 240 D-SOLD
1979 300SD

where you buy your TC from? how much?

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1982 300TD 210K miles ("The Replacement" aka "The Anvil") - SOLD
1979 300SD 245K miles (never ending project)
2007 Pinarello F3:13
1995 Ducati 916 (SOLD, sniff)
1999 Ducati 900SSie (SOLD)

just bumping this one again. Anyone can chime in. Where does one get a new/rebuilt torque converter for one of the old 722.1xx transmissions? What's a reasonable price?

thanks

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1982 300TD 210K miles ("The Replacement" aka "The Anvil") - SOLD
1979 300SD 245K miles (never ending project)
2007 Pinarello F3:13
1995 Ducati 916 (SOLD, sniff)
1999 Ducati 900SSie (SOLD)