Frankenbenz is ALIVE...hahahahahahaha

[origamitect]

Well, 3 months, ~$300 worth of beer, and ~ $450 worth of miscellaneous parts later; Frauline Frankenbenz 240D moved out of the garage under her own power. Here's the skinny on everything we did:

1) removed the completely blown 4 cyl engine
2) removed the completely good 4 sp manual transmission
3) replaced the engine with a good 5 cyl turbodiesel from an 84 300SD
4) hooked the good 4sp manual behind the 5 cyl turbodiesel
5) shortened the front driveshaft by 10.65 cm, shortened the shift linkages to fit
6) put a 2.88 rear diff from an 85 SD on the rear end.
7) shortened the 84 SD exhaust to fit under the 123 body, and did alot of welding to get exhaust hanging points.
8) cursed alot
9) hybridized the vacuum and electrical systems as best as possible
10 cursed alot more
11) new shocks all around

note: between all steps, insert "drank beer"

We've done some test driving, and amazingly it all works. 1st gear sucks, even though one can get the tires to squeal on a takeoff! Everything else is very peppy. Turbo spools up nicely at higher speeds. Ride issues were solved with new shocks. Two big issues: 1) can not get the tranny into Reverse (yes I pulled up!) if it gets close to being in reverse, then it gets all jammed up and I cant get it out again without getting under the car and fiddling with the linkages up by the gear shift lever. (note: this did not happen before the swap) 2) Engine vibration at all speeds, more noticeable @ low. We did not put add'l engine shocks on, so that may be the issue. We took it to our friendly Bosnian mechanics to diagnose. They agreed that it probably was extra engine vibration that was causing what we felt and would figure a way to dampen it. Any ideas on the linkage issue? Anyone...... Anyone? Thanks for all your help. We never would have been able to do it without this resource!

Seems that if the tranny shifted and operated properly only prior to the swap, it would be reasonable to assume that the tranny didn't just decide to loose reverse during the removal and installation into the 240.......soooo my bet would be that there is a linkage issue you have yet to resolve!

Although, there is Murphy's law, but IIIIIII, doubt it!!!!

[leathermang]

Did you shorten the linkages by exactly 4 inches ?

[pwogaman]

And of course you'll be posting the many pictures you took shortly - right?

[t walgamuth]

now 4" further back...is the linkage fouling on the tunnel? check carefully and you may have to bend something a little to get clearance.

great job!

tom w

[origamitect]

we were binding up... under the gear shift...

So, when watching someone shift through the gears from under the car, for some reason the reverse lever coming down from the gear shift above will bind on the 1-2 lever, but only when the linkage rod is there. I've adjusted the angle of the screw-on eye+grommet of the reverse linkage rod, and tried bending it - but I can't figure out why (even without the clip installed under the gearshifter) it pulls the reverse lever into thinking its 1st and gets stuck. That's what appears to be happening. Is this a spring issue in the gear shift mechanism above the linkages maybe? Maybe I just need to bend that rod way out to provide clearance b/t the two... I'll let you know if we figure it out. Meanwhile, we'll just have to be strategic about parking....haha. Any other suggestions about that mechanism are appreciated. Thanks!

Pictures of a very hoopty hybridization will come shortly, after the Bosnian Brothers have figured out engine shocks. Lets just say, velcro ties and electrical tape have become my very good friend...

[Old Geek]

After the transplant did you adjust the ALDA to near full out? THis adjustment usually improves pick-up before the |Turbo spools up...

[PagodaLover]

what an amazing project!!!

[83mercedes]

What made you want to do this conversion rather than just buying a turbo diesel and repairing the 240 or selling the body?

[boneheaddoctor]

Originally Posted by 83mercedes

What made you want to do this conversion rather than just buying a turbo diesel and repairing the 240 or selling the body?

The man had a lot of spare time on his hands.....

[t walgamuth]

that you have the shift rod in backwards?

tom w

[Whiskeydan]

Originally Posted by boneheaddoctor

The man had a lot of spare time on his hands.....

...and alot of beer.

[origamitect]

Originally Posted by boneheaddoctor

The man had a lot of spare time on his hands.....

ahem...woman.... not that it should make a difference

As far as the flywheel goes, no, we did not check neutral balance, nor did we get the entire assembly balanced. We used the flywheel from the 240D. I suppose the only way to check this is to take the tranny+flywheel+driveshaft all out again? Is the balance test like when they balance a motorcycle tire - on a shaft w/bearings to see if its heavy somewhere? Or something more scientific? If the flywheel is neutral balanced, then I would have to look somewhere else for the vibration, right?

As far as the linkage goes - took it to the mechanic to fiddle with it - he figured it was a little long and shortened it some more, now I have reverse. Problem #1 solved. Also, he said the transmission mount was a little too far forward which made any vibration from the tranny transmit directly to the body. He moved it back and put some rubber on it, and said that some of the vibration was fixed, but still some was left. He couldn't figure how to put add'l engine shocks on - but I recall looking at the skinnerbox.steaky.org site there used to be a retrofit kit for excessively vibrating engines. Does anyone know if those can still be bought? Well, anyway - thanks again - I look forward to more info from you all.

[JEBalles]

I wonder what the bounty on her husband's head is.