240D 4-speed manual swap in 300CD - PeachParts Mercedes-Benz Forum

240d jeep · #1 11-30-2007, 09:58 PM

I am running a 220d Flywheel on a 240D engine and I didnt even look for marks. If there is no pin or anything and the bolt pattern is round then it will work! I used to think this was a big deal but I built a 400 chevy a few years back with parts from around the shop (no money) had 3 diffrent kinds of pistons and 2 were 70 grams heaver than the rest and had a rebalanced flywheel from a guy that said it would work (350 with a weight) ran 50k miles no problems no vibrations turned 5500 a lot never died!

t walgamuth · #2 11-30-2007, 10:31 PM

Well, that is what I used to think too. I did several without consideration of balance and was fine.

Until we did my 280e. It was balanced with the crank for sure. It is too much work to ignore the possibility that you have the one in four or five that is balanced with the crank. I mean too much work to tear it all down if you guess wrong.

The FSM says to assume they are balanced with the crank.

Tom W

gavin_leslie · #3 11-30-2007, 11:14 PM

winmutt, t walgamuth...thanks for the info. I was hoping to have everything buttoned up this weekend, but I suppose delaying things just a bit longer to ensure that things are in balance is a good thing.

I recall a thread where there was a listing of that wires do what on the auto safety switch. Ill have to track that down again.

ForcedInduction...Its a thing that they do here at the yards. They take a paint pen and scribble something unintelligable on it just in case you wish to return it, though Im not sure why you would do that. In any case, I saw then going for the flywheel surfaces and gritted my teeth a bit...nothing that cant be taken care of with a rag and brake parts cleaner.

Im pleased to hear that there seems to be a decent group of people who have done this to success. My main concern about doing this was(especially in light of possible added vibration) was a reduction in longevity/durability. The last thing that I wish to do is wreck the cars propensity for reliability.

Driveshaft picked up today. Shortened and balanced with new guide pin bushings. The paint has barely dried on it.

Gavin

Austin85 · #4 11-30-2007, 11:28 PM

As I have written here I have a 4spd from a 240 that I wanted to have put into my 82 300CD, (which BTW slips in 2nd and now will eventually need a rebuild, I am told.)

I got it fom Bruce K. and my ex- indie told me he would do the swap for around 500., so I purchased it with this in mind & budget.

When I got it my EX- Indie tells me he never said 500. He says 1,500

I have recently asked another very experienced shop that does these type of mods all the time, and he also said 1500 + possible other ancillary costs.

I do not have the room or experience mechanically to do it myself, so can anyone tell me if this 1,500 range is reasonable or high.......or low. for a good job.

Thanks,
AA

t walgamuth · #5 12-01-2007, 12:25 AM

I think I paid my indie about $700 and that included 175 for lengthening the driveshaft (or was it shortening?). Anyway they made a new ds with my old ends.

Tom W

gavin_leslie · #6 12-01-2007, 03:10 AM

managed to get half of the stuff I ordered in preparation for the transplant.

I took a guess at the shift linkage bushings and lucked out(theres a lot of bushings to choose from), new pilot bearing, driveshaft coupler boot thingie and a new shift knob.

Im not sure what the deal was, but there were four 240Ds in the local yards and all of them were missing their shift knobs. Is this a rare item that fetches a kings ransom on the black market? I was lucky it seems that the 240 I was working on still had the shift mechanism itself. All the other 240s had theirs swiped...not the transmissions mind you, just the shifters and shift linkages.

The other half of the parts I ordered were two rebuild kits for the clutch master and slave cylinders. They should be arriving at the start of the week.

Yeah, I think this may turn out pretty well indeed.

Gavin

t walgamuth · #7 12-01-2007, 08:42 AM

The shifters never really wear out but they have a bushing that does. It is a bit of a job to change it. Folks who don't realize it is a $2 part might just get a new shifter. The knobs do sometimes fracture and a new one costs over $40. It looks like you are nearly ready.

Good luck.

On a car this old it is a hugley better deal running the unbreakable stick tranny vs trying to get an old automatic right. The automatics are about bulletproof but if they don't get the fluid and filters changed religeosly per the book they will begin to malfunction before 100k miles.

Tom W

winmutt · #8 12-02-2007, 07:38 PM

Quote:

Originally Posted by t walgamuth

The shifters never really wear out but they have a bushing that does.

You are referring to a bushing inside the shifter itself? I have only seen one shifter with the reverse lockout that worked properly. It is going into my car as a replacement for the one I have.

I saw a 116 v8 with a stick at the yard today!!!

estod · #9 12-17-2007, 07:35 PM

Speaking of maintenance, remember to change the oil in the manny tranny every 10K. An old dealer mech told me to use ATF. I have used that, but now use Mobil 1 10-30 per Larry Bible. It seems to work fine. I still change it every 10K.

MTUpower · #10 12-01-2007, 09:46 AM

Quote:

Originally Posted by t walgamuth;

I think I paid my indie about $700 and that included 175 for lengthening the driveshaft (or was it shortening?). Anyway they made a new ds with my old ends.

Tom W

Depends on the Indie. I would think to take out your automatic, figure out the parts of the manual you have and install it would take at least 10 hours- more like 15. $100 an hour = $1500. If you leave the car and he can do it when he's not doing other work perhaps $700. $500? Not in South Florida if you ask me.

t walgamuth · #11 12-01-2007, 10:09 AM

Perhaps it helps that my indie has been doing oddball mercedes related things for me for a good long while. This is not the first stick conversion he has done for me.

Tom W

t walgamuth · #12 12-01-2007, 10:11 AM

Oh, and be sure he uses the stick flywheel bolts because the automatic bolts are a bit longer and if he puts them in the motor won't turn over!

IIRC new flywheel bolts are recommended, but sometimes they can be measured at the neck for stretch and if they pass can be reused.

Tom W