Hi, I just purchased 240D 4 speed.


It seems that the clutch is not disengaging completely. When I put it in reverse with clutch fully depressed it grinds gears. Also It works better if I double clutch when I change gears.
Today it was almost impossible to get it in any gear and the clutch seemed to be very deep before it built up pressure.
It cahnges gear fine when the engine has stopped.

I checked the fluid level and it is completely full.


The dead traveled of the clutch is about halfway.
I checked under the dash and under the car for leaks but found nothing.

I readjusted the eccentric bolt on top of the master cylinder to get a little more pressure stroke out of the clutch.

I noticed that the rubber clutch hose under car get a little shorter ( 1/8" -1/4")when you push the clutch pedal. For the rest the hose looks fine.
Is that normal?

Any other suggestions?

Thanks Johan

__________________
85 MB 300TD with om616 4 spd
83 MB 300TD
83 MB 240D scrapped
82 MB 240D scrapped
97 Ford E350 diesel 4x4, WVO
94 Ford E350 4x4 diesel blown head..parts car
85 cherokee diesel 2.1, 300.000, WVO
85 cherokee diesel 2.1
85 lebaron convertible, to be electric
85 lada niva 4x4 with 1.9 peugeot diesel,
72 citroen DS 5spd, LPG
77 Jaguar XJS, LPG
73 corvette 350 auto
88 MB Gelande 240 GD military
98 Ford E350 mini bus to be new 4x4 camper

Not sure what to tell you but I ended up having to replace mine. Here's a write up I did that may be helpful if it comes to that for you:

http://www.peachparts.com/Wikka/OM616Clutch240D

Scott

__________________
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)

If it were me , the next thing I would try is bleeding the slave cylinder.

If that didn't work, next in order of least pain/expense would be to replace the slave cylinder.

After that- your options are limited- rip the mess apart and have a look.

Are you sure your transmission linkage is working properly?

Rick

__________________
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 (??)

Hi folks,

Scott98, what a great article, as soon as determined that the clutch has to be replaced it will be a great help to me.


RS899 , The linkage bushing are gone. hat was my first thought (Learned that form reading on this great forum) I ordered new ones, with memorial day it will be next week before i will get them. But I think it is in the hydraulics.

Yesterday I read a post about pumping the clutch very fast adn it would bring the pedal up. It does . I though it was written that the master is bad but....
I can not find the post back anymore to give the person some thanks and re -read the hole story.

Did I PM you about your DS19?

Thanks Johan

__________________
85 MB 300TD with om616 4 spd
83 MB 300TD
83 MB 240D scrapped
82 MB 240D scrapped
97 Ford E350 diesel 4x4, WVO
94 Ford E350 4x4 diesel blown head..parts car
85 cherokee diesel 2.1, 300.000, WVO
85 cherokee diesel 2.1
85 lebaron convertible, to be electric
85 lada niva 4x4 with 1.9 peugeot diesel,
72 citroen DS 5spd, LPG
77 Jaguar XJS, LPG
73 corvette 350 auto
88 MB Gelande 240 GD military
98 Ford E350 mini bus to be new 4x4 camper

Long time ago, finally got to it, it is worse when it is colder.
Took the slave apart and found the seal in bad shape.
Replaced it and it is fine.
I do not know if the old slave is original but the grooves on the push-rod go way further past the slot in under the shim of the slave cylinder. ( 5MM )
According to the manual the clutch must be replaced.
Nevertheless it works fine.
The push rod rounded head was worn unevenly.
Because of time I I ended up replacing the Piston with seal of the "original?? slave with an older piston / seal from a mercedes manual transmission that has a separate bell housing . Anybody any idea what mercedes this can be off?
Interesting the "original" slave did not have a spring inside, the unit of the older ? mercedes did have a spring inside the slave that I installed in the slave of my 240D.
The cast iron cylinder housings of the slave are similar but the bolt holes on the 240 D unit are offset. The other unit are in line.
can anybody shed some light on this?
Thsk

__________________
85 MB 300TD with om616 4 spd
83 MB 300TD
83 MB 240D scrapped
82 MB 240D scrapped
97 Ford E350 diesel 4x4, WVO
94 Ford E350 4x4 diesel blown head..parts car
85 cherokee diesel 2.1, 300.000, WVO
85 cherokee diesel 2.1
85 lebaron convertible, to be electric
85 lada niva 4x4 with 1.9 peugeot diesel,
72 citroen DS 5spd, LPG
77 Jaguar XJS, LPG
73 corvette 350 auto
88 MB Gelande 240 GD military
98 Ford E350 mini bus to be new 4x4 camper