I am in the middle of my 4-speed converson ('85 300cd), and have a few quick questions.

1. what size pilot bearing do I need for the drive shaft.

2. I found that the new manual trans is 6.5 inches shorter than the auto. Is there any reason I just can't get the front side of the drive shaft extended that much?

3. What do you guys use for fluid in the manual trans?

4. Might be a stupid question, but which part is the flexplate? I have seen it talked about in several threads, but want to make sure I get it right. Is it the same as the pressure plate?

So far, I have tore everything down, and want to start putting things back together this weekend. I need to get all new bolts, clutch, etc.

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My Primary Driver - '85 300CD - 4-speed conversion, 2.47 rear, lowered, euro headlights, rebuilding (not restoring so much)

Wife's - '08 Saab Sportcombi Aero

Riding a '03 Yamaha Warrior

You are doing this without access to a Factory Shop Manual ?
Redline MT fluid is used by many.

The FSM is of no use in this conversion. You are in territory unacknowledged by the factory.

GO here: Auto -> manual conversion

Most if not all will be revealed in that thread.

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Never a dull moment at Berry Hill Farm.

It will at least give the names of the items in question... and speaks about balancing...

How have you sorted the small pilot bearing issue?

I just heard of that last night cruising through the superturbodiesel forum. What exactly am I going to be doing? From what I have gathered , I am going to be taking a grinder to the outside ring to make it fit into the 300's engine.

And thanks a ton for that thread RLeo. I have been studying that one before getting started...I don't think I ever made it all the way through yet though....HAHA

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My Primary Driver - '85 300CD - 4-speed conversion, 2.47 rear, lowered, euro headlights, rebuilding (not restoring so much)

Wife's - '08 Saab Sportcombi Aero

Riding a '03 Yamaha Warrior

Lengthening the front part of the driveshaft is the correct proceedure.

Tom W

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[SIGPIC] Diesel loving autocrossing grandpa Architect. 08 Dodge 3/4 ton with Cummins & six speed; I have had about 35 benzes. I have a 39 Studebaker Coupe Express pickup in which I have had installed a 617 turbo and a five speed manual.[SIGPIC]

..I also have a 427 Cobra replica with an aluminum chassis.

I know I have to lengthen the drive shaft to reach the new trans, is there something else I should be doing to it?

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My Primary Driver - '85 300CD - 4-speed conversion, 2.47 rear, lowered, euro headlights, rebuilding (not restoring so much)

Wife's - '08 Saab Sportcombi Aero

Riding a '03 Yamaha Warrior

Rebalance both driveshafts as a unit.

Depending on where you found the transmission, you may need to modify or replace the linkages (3).

Coupes have a shorter wheelbase than the sedans. Wonder if there is a sedan driveshaft that would work?

Jim

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14 E250 BlueTEC black. 45k miles
95 E320 Cabriolet Emerald green 66k miles
94 E320 Cabriolet Emerald green 152k miles
85 300TD 4 spd man, euro bumpers and lights, 15" Pentas dark blue 274k miles

I think the difference is in the back part of the ds.

Tom W

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[SIGPIC] Diesel loving autocrossing grandpa Architect. 08 Dodge 3/4 ton with Cummins & six speed; I have had about 35 benzes. I have a 39 Studebaker Coupe Express pickup in which I have had installed a 617 turbo and a five speed manual.[SIGPIC]

..I also have a 427 Cobra replica with an aluminum chassis.

PLease explain your question #2.

Tom W

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[SIGPIC] Diesel loving autocrossing grandpa Architect. 08 Dodge 3/4 ton with Cummins & six speed; I have had about 35 benzes. I have a 39 Studebaker Coupe Express pickup in which I have had installed a 617 turbo and a five speed manual.[SIGPIC]

..I also have a 427 Cobra replica with an aluminum chassis.

Rumors of some W116 drive shafts being the correct ones have surfaced before.

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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

With Q#2, I have been told that the drive shaft place will want me to take a total length of the driveshaft needed. I found that the manual is 6.5" shorter than the auto...I wanted to know if that will work (extending the front side by 6.5") or if there is something I didn't think of, and need to measure what I need with the new trans in place.

When you said that, I didn't know what you were speaking of. I wanted to make sure there wasn't something else I needed to do.

I am planning on sending the whole shaft to the place in San Antonio that RLeo sent his to. Funny story actually, there is a driveshaft place here in Shreveport, LA...but they refuse to work on anything European. They seem to think that it is going to cost me around $800 to get it done.

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My Primary Driver - '85 300CD - 4-speed conversion, 2.47 rear, lowered, euro headlights, rebuilding (not restoring so much)

Wife's - '08 Saab Sportcombi Aero

Riding a '03 Yamaha Warrior

Is a w123 240d 4spd conversion done the same way or are there differences from a 300d?

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1981 240D 143k 4 spd manual -SOLD

2004 VW Jetta TDI 5 speed 300k -still driven daily