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  #1  
Old 03-24-2009, 05:45 PM
klaus kallas's Avatar
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300D 2.5 Turbo 5-speed conversion?

OK,

So I have a '93 2.5 turbo with an almost baked automatic. Have another in the garage I can toss in there, but in the yard there is an '84 190E 5 speed parts car with a fine tranny. If I'm going to have the auto. out anyway, it would be mighty nice to convert it.

Has someone done this on a 602 or 603 124 chassis car? Just from a quick check, the pedals, shifter and tranny will bolt up. Driveshaft and crossmember will need to be customized. What am I missing? Done auto to manual conversions on 123 and 201 cars with results, but haven't gone across chassis before....

Thanks!

Klaus

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  #2  
Old 03-24-2009, 07:10 PM
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5 speed

had you lived a little closer to houston, i was going to buy that parts car from you. we talked a while ago, but alas it is to far for me to be able to get it.

so from all that i have read, everything should bolt up, but it is advised to get a diesel flywheel, if you are merging a gasser 5 speed to a 2.5T. also the driveshaft is supposed to bolt up together just fine as well with no mods. the front of the driveshaft from the 5 speed needs to be connected to the the rear of the diesel. or i guess just move the whole thing from the gasser. either way, should be straight forward.

Cough cough
for anyone in texas or bordering states, i will buy your 5 speed parts car
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  #3  
Old 03-24-2009, 07:18 PM
ForcedInduction
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Yep, you should just need a diesel flywheel and maybe slight modification to the driveline for it to work.
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  #4  
Old 03-24-2009, 10:48 PM
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Quote:
Originally Posted by arcticathlon View Post
had you lived a little closer to houston, i was going to buy that parts car from you. we talked a while ago, but alas it is to far for me to be able to get it.
As it turns out, this 300D got dropped in my lap and I'm glad I still have the parts car!! Can't wait to get this project started! There are still a few out there and I'm sure you will come across one closer to you.

I also have a 190D 2.2 manual (tranny only), and looking at the ratios it appears the first four gears are almost spot on the '93 2.5 auto with, of course, the addition of a 0.84 overdrive. Sounds like a winner!

Klaus
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'62 300d Adenauer-350 Chevy - "Max"
'15 VW Passat TDI
'16 Dodge Ram 3500 - Cummins w/6-speed
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'55 T-bird
‘63 Studebaker Hawk
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Old 03-24-2009, 11:02 PM
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Didn't some 190D 2.5's come with a 5 speed? If that's the case, then getting the correct flywheel shouldn't be a big issue like it is for a 617.
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  #6  
Old 03-25-2009, 12:02 AM
klaus kallas's Avatar
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Quote:
Originally Posted by lietuviai View Post
Didn't some 190D 2.5's come with a 5 speed? If that's the case, then getting the correct flywheel shouldn't be a big issue like it is for a 617.
Not a lot of 5 speed 190d 2.5's in the junkyard, at least around here! 616 flywheels are common enough, won't they bolt on a 617?
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‘84 300TD “Mountain Goat”
'62 300d Adenauer-350 Chevy - "Max"
'15 VW Passat TDI
'16 Dodge Ram 3500 - Cummins w/6-speed
'68 Mustang fastback
'55 T-bird
‘63 Studebaker Hawk
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  #7  
Old 03-25-2009, 11:06 AM
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Quote:
Originally Posted by klaus kallas View Post
Not a lot of 5 speed 190d 2.5's in the junkyard, at least around here! 616 flywheels are common enough, won't they bolt on a 617?

190D manual flywheels are very common on Ebay.de, the 300D flywheels are not. you will get differing opinions on whether the 240D flywheel is ok on a 300D, it bolts up, but it is 10 pounds lighter.
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  #8  
Old 05-15-2009, 02:56 PM
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Yeah! It is almost done. Tranny, pedals, and shifter are in and it runs and goes through all the gears!

However, my source for the correct driveshaft fell through. Will weld one up this weekend (thanks crashone!!) unless someone has an extra 300E or 190 2.6 5-speed front shaft lying around......? The old 2.3 shaft from my donor car is of a smaller diameter, and I've been trying to mix and match to get something to fit, but it appears I need one of the above.

Hope to test drive Sunday afternoon! Stay tuned!

Klaus
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‘84 300TD “Mountain Goat”
'62 300d Adenauer-350 Chevy - "Max"
'15 VW Passat TDI
'16 Dodge Ram 3500 - Cummins w/6-speed
'68 Mustang fastback
'55 T-bird
‘63 Studebaker Hawk
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  #9  
Old 05-18-2009, 07:51 PM
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It works!! Installed the newly fabricated driveshaft ( crashone IS the man! Thanks!!!!!) yesterday and took her for a spin. No weird noises and no vibrations!

Drove to work today, and everything is well except the gearing. Had to use a 190E 2.3 tranny with taller gearing, and with the 2.65 rearend it is a *bit* overgeared (2300 rpms at 70, and that's in 4th ) . Already have plans to put in a 3.27 from a 300TE, but just wanted to get it mobile again.

When I get a chance, I'll post a parts list for anyone else interested in this swap.

Klaus

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‘84 300TD “Mountain Goat”
'62 300d Adenauer-350 Chevy - "Max"
'15 VW Passat TDI
'16 Dodge Ram 3500 - Cummins w/6-speed
'68 Mustang fastback
'55 T-bird
‘63 Studebaker Hawk
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