Quick update.

Almost 3 years down the road.....Chug Chug Chugging along.

That is all

Gavin

617a + manual trans. = awesome

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1983 240D 3.0T 4-speed manual, now sold

1989 Subaru GL Wagon 5-speed Touring Edition

X2.

Great thread. Nice write up.

I hope to have a manual tranny behind a Diesel benz. Good stuff.

__________________
85 300D 3 pedal. Current project.
83 300TD (need rear wiper assembly dead or alive)
84 300SD Daily driver
85 300TD almost 400k miles and driven daily.
98 E300D *sold
86 300SDL *sold and made flawless 10 hour journey to new home.

You should try it with the 87

__________________
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

Glad to hear it's working well. The 81 240D 4spd that I put the 300D engine in for my son has been nearly flawless for 10000 miles now, no drips, cold AC and starts and runs perfect.

Dan

__________________
81 240D 4speed with 300D engine
87 560SL
2005 E320
Yukon Denali
Sierra Denali
850 Turbo Volvo
1996 Mustang
1984 Mustang race car
3 Boats

I was skimming through this thread again and and noticed in Post# 35, Gavin used the 240D manual transmission X mount, and modified it to fit.

Use the X mount from a 240D automatic. It is wider and uses 4 17mm bolts. actually the next set of mounting holes back.

He also shows using the plug from the Nutral safety switch (NSS) and making a plug adaptor.

I removed the NSS plug/harness where it comes through the body, RTV`d thehole closed. there is a plug connector above the carpeted pannel above the drivers knee.
The back up light switch plug, from the shifter assembly, plugs into this plug above the drivers knee.

There are 2 purple wires that are for the starter, and the other 2 in the plug are for the back up lights.

This is a great write up, and I don`t want to take away from what he did.

Charlie

__________________
there were three HP ratings on the OM616...

1) Not much power
2) Even less power
3) Not nearly enough power!! 240D w/auto

Anyone that thinks a 240D is slow drives too fast.

80 240D Naturally Exasperated, 4-Spd 388k DD 150mph spedo 3:58 Diff

We are advised to NOT judge ALL Muslims by the actions of a few lunatics, but we are encouraged to judge ALL gun owners by the actions of a few lunatics. Funny how that works

Someone had a great idea of a kill switch. My grandfather had every benz of his equipped with a kill switch. It looked like any other switch on the console but when off killed the starter. I have the wagon console in my 87 and I think I am going to do this. Cant think of anything else to do with the hole other than find an auto rear window screen in red.... Not so easy I think.

__________________
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

Sorry to reply to an old post, but I've just completed an auto to stick swap in a 1983 300D.I just wanted to say that the information I found here was invaluable during this conversion and that the 300D with a stickshift is a completely new animal.So much snap off the start and SO much more enjoyable to drive.

There were a few small differences, such as my brake pedal hooked right up instead of modifying a bushing, but everything else was right on and gave me a good idea of what to expect during the job.I must say though, I'm used to Volkswagens and DAMN are these Benzes built!

Thank you so very much for posting this and all the great pictures.Also, my magic number for the driveshaft and linkage shortening was four inches.

Again, thanks a million.

Heliarc

Think you are refering to pg 3 post#36. when I did my 4 spd swap into the 85 300D, I didn`t have any problems with the bushing. as I remember, it all went together.

As far as the NSS goes, just unplug it and pull the cable out of the cabin.
there is a plug connection behind and at the top of the carpet above the drivers knee. the wire with the reverse light plug from the shifter plugs into this plug connection.
there are 4 wires in this plug, 2 are yellow black or something like that, they are the reverse.

The other two are purple/white or something like that. just make a jumper across these for the start of the engine.

Then the NSS plug and cable can be removed and the hole in the tunnel can be sealed with RTV.

Glad to see we have another happy customer. welcome to the forum.
Hope to see you around for a long while.

Charlie

__________________
there were three HP ratings on the OM616...

1) Not much power
2) Even less power
3) Not nearly enough power!! 240D w/auto

Anyone that thinks a 240D is slow drives too fast.

80 240D Naturally Exasperated, 4-Spd 388k DD 150mph spedo 3:58 Diff

We are advised to NOT judge ALL Muslims by the actions of a few lunatics, but we are encouraged to judge ALL gun owners by the actions of a few lunatics. Funny how that works

Hey all,

Great thread and very informative on conversion. I haven't done a swap on a W123 but did bring in a 5 speed from Holland and did a swap on my diesel Passat. 2005.

I did a shade tree restore on 300d 1985 with my son in high school. It was his first car and he loved the cool factor and all the questions.
I sold it when he went away to college and he was kinda annoyed.

Well he is in the workforce now and doing well and just the other night he mentioned the Mercedes and how he would like to try and find another . He was actually grateful for all the work I put into it and getting him on the road.
Guess hindsight and getting older makes you somewhat wiser.

Anyways we have an eye on a car and going to see it at the weekend.

I would love to do a conversion but was wondering if there's a 5 speed option available.

Even if I have to bring one in from Europe. I have a decent guy in Holland that can source it and get all the parts if I give him a list.

Chris

If you have all the pieces ready to go, the w123 swap will be much more straight forward than the Passat TDI swap.

Yes, 5 speeds are available for the w123.
But if you are talking about a 5 speed for a w123 powered by a diesel om616 or om617 and a gasser m110, it is rare. The 5 speed trans you want is a 717.400.

I am guessing you mean Frans when you are talking about the source in the Netherlands.
He has a good chance of getting one and possibly the whole swap like he does for the Passat. But again the 717.400 are rare, so it may take sometime for him to locate one.

However, this fella is selling a whole car in the states...

http://www.peachparts.com/shopforum/mercedes-used-parts-sale-wanted/383397-5speed-euro-240d.html#post3745032

If you get this car as a parts car and are using a 617 or 110 motor you'll need to source the shift rods, driveshaft, flywheel for the m110 and possibly the 617 flywheel if you want to use a heavier unit.


.

__________________
1983 123.133 California
- GreaseCar Veg System

Hey deliveryvalve,

Thanks for reply. Yeah I'm talking about Frans.... you're probably familiar with him over on TDI club I guess. Great guy and very reasonable on prices.
Plus the $ is a little stronger against Euro so that helps.

I'm currently just thinking out loud and haven't done much wrenching in a while.
I'm not that familiar with the numerical value on the 123 motors.

Can I match up that 5 speed to the 300 turbo or does it only mate up to the naturally aspirated earlier models?
Do you currently have a stick in yours?

The 5 cylinder turbo motor on a 300D,TD,CD is a 617.952 and a 717.400 5 speed transmission can bolt right up to it.
However, the 717.400 was never bolted to a turbo motor. Its originally bolted to the naturally aspirated 5 cylinder 617.912 (300D, TD, CD), 4 cylinder 616.916 (240D, TD) and the 6 cylinder 110.988 (280E, TE, CE).


No, I don't have a 5 speed in the car. But I have all the parts to make one.
.

__________________
1983 123.133 California
- GreaseCar Veg System