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  #1  
Old 08-07-2009, 02:03 PM
pawoSD's Avatar
Dieselsüchtiger
 
Join Date: Oct 2004
Location: Grand Rapids, MI
Posts: 15,315
Thumbs up She's back on the road!!

Well, after days and days (some of them 12-13 hours of continuous work)....my SD is back on the road!! I finished it up last night, and did fine tuning this morning....and it drives perfect.

The original transmission lost reverse and then began dying quickly a few weeks ago, missing shifts, disengaging at random....bad sounds...etc. So I pulled it off the road and swapped transmissions. I put in a 1985 300D transmission which required a tail housing swap (not too bad of a job)...it only had 163k on it, and it shifts great! The car has a whole different (faster and better!) feel with the 1985 high stall speed torque converter. It can really move off the line now! I would not hesitate to say from 0-25 it is faster than my 300E....

I was able to pull off the task for less than 1/3 the cost of a rebuilt transmission, including buying: the trans itself, an engine crane (2 ton)...two separate orders of parts....and various cleaners and rags and supplies. I am quite pleased with that!

I took random pictures......they are all on my phone so I will load them either later today or on Sunday (leaving for a camping trip in a few hours)....

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-diesel is not just a fuel, its a way of life-
'15 GLK250 Bluetec 90k - mine - (OC-91,200)
'17 Metris(VITO!) - 18k - wifes (OC-25k)
'01 E320 Wagon - 161k - mine (OC-165,000)
'01 E320 - 180k - dad's (OC-182,500)
'07 E350 Wagon - 134k - dad's (OC-139,500)
'01 SL500 - 56k - dad's (OC-59,000)
'16 E400 4matic Sedan - 81k - Brothers (OC-88,000)
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  #2  
Old 08-07-2009, 02:32 PM
Admiral-Third World Fleet
 
Join Date: Feb 2002
Location: Central FL
Posts: 3,068
It will be interesting to see what caused the failure on the old one- let us know what you find out. Hopefully you won't be scared of rebuilding it when the time comes ( or the '85) after you realize that there aren't any demons in there.

Rick
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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 (??)
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  #3  
Old 08-07-2009, 02:46 PM
tbomachines's Avatar
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Join Date: Mar 2009
Location: Philadelphia
Posts: 6,660
Nice! Definitely interested in the pictures and disassembly of the old one.
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Current stable:
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Past: 135i, GTI, 300E, 300SD, 300SD, Stealth
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  #4  
Old 08-07-2009, 04:33 PM
DeliveryValve's Avatar
Chairman of my Benz
 
Join Date: Jun 2006
Location: Central California
Posts: 4,143
Good job. Did you make any adjustment with the vacuum modulator or kept it as is?

Glad it worked out.
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  #5  
Old 08-09-2009, 12:05 AM
pawoSD's Avatar
Dieselsüchtiger
 
Join Date: Oct 2004
Location: Grand Rapids, MI
Posts: 15,315
Quote:
Originally Posted by DeliveryValve View Post
Good job. Did you make any adjustment with the vacuum modulator or kept it as is?

Glad it worked out.
I adjusted the modulator about 2 clicks firmer....but it shifts great. The weirdest part is how the high-stall torque converter works...I just need to get used to it.

Eventually I will rip into the old trans....it is well past being saved. It sat in the rain with covers missing and such....not worth saving. Either way I will pull it apart and try to take some pics/see what happened.

I am guessing that a clutch disc failed or something....based on the chunk of metal I found in the pan, and the clumps of gray silt/clutch material.
__________________
-diesel is not just a fuel, its a way of life-
'15 GLK250 Bluetec 90k - mine - (OC-91,200)
'17 Metris(VITO!) - 18k - wifes (OC-25k)
'01 E320 Wagon - 161k - mine (OC-165,000)
'01 E320 - 180k - dad's (OC-182,500)
'07 E350 Wagon - 134k - dad's (OC-139,500)
'01 SL500 - 56k - dad's (OC-59,000)
'16 E400 4matic Sedan - 81k - Brothers (OC-88,000)

Last edited by pawoSD; 08-09-2009 at 01:18 PM.
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  #6  
Old 08-09-2009, 12:35 AM
bsmuwk's Avatar
124.051
 
Join Date: Jan 2009
Location: IL / WI
Posts: 967
So that morning drive was definitely worth it eh?
Now I just have to find a buyer for that gem of an engine.

Oh and by the way, when tearing into your old transmission, any bad clutch disks will be an almost blue color, almost like they've been bruised. When you're tearing into it, make sure you have a nice space to work in and put the transmission guts on.

Trust me on that. You'll need all the space you can get if you're going in for the first time.
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Lakemoor, IL
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Last edited by bsmuwk; 08-09-2009 at 12:45 AM.
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  #7  
Old 08-09-2009, 01:19 PM
pawoSD's Avatar
Dieselsüchtiger
 
Join Date: Oct 2004
Location: Grand Rapids, MI
Posts: 15,315
Quote:
Originally Posted by bsmuwk View Post
So that morning drive was definitely worth it eh?
Now I just have to find a buyer for that gem of an engine.

Oh and by the way, when tearing into your old transmission, any bad clutch disks will be an almost blue color, almost like they've been bruised. When you're tearing into it, make sure you have a nice space to work in and put the transmission guts on.

Trust me on that. You'll need all the space you can get if you're going in for the first time.
If I tear into it, I won't be intending to put it back together, so I'll probably just dump parts in a bucket.

That drive was indeed worth it! It works beautifully. Thanks again!
__________________
-diesel is not just a fuel, its a way of life-
'15 GLK250 Bluetec 90k - mine - (OC-91,200)
'17 Metris(VITO!) - 18k - wifes (OC-25k)
'01 E320 Wagon - 161k - mine (OC-165,000)
'01 E320 - 180k - dad's (OC-182,500)
'07 E350 Wagon - 134k - dad's (OC-139,500)
'01 SL500 - 56k - dad's (OC-59,000)
'16 E400 4matic Sedan - 81k - Brothers (OC-88,000)
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  #8  
Old 08-10-2009, 10:46 AM
pawoSD's Avatar
Dieselsüchtiger
 
Join Date: Oct 2004
Location: Grand Rapids, MI
Posts: 15,315
Here's a few pictures of what I found in the pan when I took it off of the old transmission: One edge is smooth, the other jagged like it broke off.....what is it from?







New bowden cable installed on new transmission, its actually quite easy to replace...



New wastegate hose (they're expensive! ) for the motor....it had needed this for a while:



Nice shiny bowden cable adjustment:



A/C compressor delete: So far this year we've only had about 4 days over 85 degrees....no need for A/C here



Neat shot of the exhaust turbine in the turbo....




That's about all the pics I took, I was working at a vicious pace to get the car done by the weekend, so little time to stop and take pics. It drove beautifully this past weekend on my camping trip....have put over 220 miles on it so far!
__________________
-diesel is not just a fuel, its a way of life-
'15 GLK250 Bluetec 90k - mine - (OC-91,200)
'17 Metris(VITO!) - 18k - wifes (OC-25k)
'01 E320 Wagon - 161k - mine (OC-165,000)
'01 E320 - 180k - dad's (OC-182,500)
'07 E350 Wagon - 134k - dad's (OC-139,500)
'01 SL500 - 56k - dad's (OC-59,000)
'16 E400 4matic Sedan - 81k - Brothers (OC-88,000)
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  #9  
Old 08-10-2009, 11:15 AM
Admiral-Third World Fleet
 
Join Date: Feb 2002
Location: Central FL
Posts: 3,068
The mystery piece of metal looks like about an eigth of a retaining "spring" from one of the clutch packs. The other 7/8ths of it may be floating around inside somewhere, causing havoc, or maybe that clutch pack is now very loose, causing the problems.

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 (??)
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  #10  
Old 08-10-2009, 11:54 AM
pawoSD's Avatar
Dieselsüchtiger
 
Join Date: Oct 2004
Location: Grand Rapids, MI
Posts: 15,315
Quote:
Originally Posted by rs899 View Post
The mystery piece of metal looks like about an eigth of a retaining "spring" from one of the clutch packs. The other 7/8ths of it may be floating around inside somewhere, causing havoc, or maybe that clutch pack is now very loose, causing the problems.

Rick
Interesting, makes sense, since 4th gear and reverse were in the worst shape when it was still in operation....4th was always questionable on that trans though, it did not have a "firm" engagement....it'd require letting off the throttle to get it to engage.

The new trans firmly shifts into each gear, its awesome.

__________________
-diesel is not just a fuel, its a way of life-
'15 GLK250 Bluetec 90k - mine - (OC-91,200)
'17 Metris(VITO!) - 18k - wifes (OC-25k)
'01 E320 Wagon - 161k - mine (OC-165,000)
'01 E320 - 180k - dad's (OC-182,500)
'07 E350 Wagon - 134k - dad's (OC-139,500)
'01 SL500 - 56k - dad's (OC-59,000)
'16 E400 4matic Sedan - 81k - Brothers (OC-88,000)
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