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  #1  
Old 05-31-2010, 12:18 PM
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Location: Syracuse, NY
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Unhappy day of bad luck

So I go to get my 83 240D yearly state inspection and to my suprise they wouldnt pass it. Turns out my rear brake pads were wore, and the pins holding them in are pretty well rotted out. The previous owner even had a nail in one of the calipers that was holding pads. This didnt seem to amuse the inspectors.

Then a day later when I'm about to go find new pads, the car wont reverse. Its a manual. The knob will go into reverse, but its completely loose and clearly isn't engaging the gear. 1st, 2nd, 3rd, and 4th all engage just fine.

So couple questions: 1. Can I get those brake pad pins separately or am I stuck getting new calipers. and 2. Why wont my transmission reverse! Thanks guys!

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1982 240D - 251,000 miles (all parts pulled and for sale, body crushed )
1983 240D 4 speed manual - 233,000 miles
2001 Ford Ranger XLT 4WD
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  #2  
Old 05-31-2010, 12:24 PM
Biodiesel300TD's Avatar
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You can buy a rear brake hardware kit that had the spring and pins.
-http://www.allpartsexpress.com/ShopByVehicle.epc?q=1982-MERCEDES--BENZ---40d--/--L4_--.4l_diesel-Brake--Components--Wheels&yearid=1982&makeid=MERCEDES+BENZ%40%40MERCEDES+BENZ%40%40X&engineid=1192991%40%40240D++%2F+L4%5F2%2E4L%5FDIESEL%40%40240D&catid=Brake+Components+%26+Wheels&subcatid=Rear%20Brake%20Pad%20Hardware%20Kit&mode=PA

As for shifting, I'll rule out the obvious first. You have to pull up on the knob then put it into reverse. Are you doing that?
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  #3  
Old 05-31-2010, 12:36 PM
toomany MBZ's Avatar
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You may have a bushing or lever issue.
Those pins are available separately. Part #000 991 03 60
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day of bad luck-shift-linkage-001.jpg   day of bad luck-shift-linkage-002.jpg  
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  #4  
Old 05-31-2010, 01:56 PM
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Quote:
Originally Posted by Sam82MB240D View Post
So I go to get my 83 240D yearly state inspection and to my suprise they wouldnt pass it. Turns out my rear brake pads were wore, and the pins holding them in are pretty well rotted out. The previous owner even had a nail in one of the calipers that was holding pads. This didnt seem to amuse the inspectors.

Then a day later when I'm about to go find new pads, the car wont reverse. Its a manual. The knob will go into reverse, but its completely loose and clearly isn't engaging the gear. 1st, 2nd, 3rd, and 4th all engage just fine.

So couple questions: 1. Can I get those brake pad pins separately or am I stuck getting new calipers. and 2. Why wont my transmission reverse! Thanks guys!
When I had my 240d, I had the same issue with reverse. If it turns out not to be a bushing in the linkage, then it might be the reverse band adjustment on the transmission. The lock nut on the adjustment had loosened up, and I had no reverse, but all forward gears were functional. All it took was a slight adjustment and tightening the locknut and all was well. Good luck
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  #5  
Old 05-31-2010, 02:18 PM
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Definitely pulling up on the knob, just way too much play once in reverse and definitely not grabbing the gear. I havent gotten under the car yet so I'll check bushings and adjustments. I appreciate the replies.

Found out most of the local parts stores have the brake pad pins in stock so thats at least a little good news.
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1982 240D - 251,000 miles (all parts pulled and for sale, body crushed )
1983 240D 4 speed manual - 233,000 miles
2001 Ford Ranger XLT 4WD
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  #6  
Old 05-31-2010, 02:36 PM
JB3 JB3 is offline
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check underneath on the transmission to see if the linkage bar is still hooked up. on the 4-speed, you have three bars, two bars control 1, 2, 3, and 4, but the third bar controls only reverse. If it fell out or the linkage bushing wore out, it would create exactly this problem.

The stick would still sort of feel like something was happening because it has a lockout mechanism right there under the handle, so it would still "feel" like it were shifting into reverse, only much easier.

My guess is that one of the little spring clips rotted out and the bar popped off underneath.

Especially in syracuse, where i also live part of the time you could have extensive linkage rusting, and the little spring clips can't take much of that
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Old 06-03-2010, 09:34 AM
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Thats exactly what it was! One of those spring clips is missing (along with the bushing) and the bar popped off.

Ordered a few clips and bushings from Fastlane. Should be good to go!

Thanks!
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1982 240D - 251,000 miles (all parts pulled and for sale, body crushed )
1983 240D 4 speed manual - 233,000 miles
2001 Ford Ranger XLT 4WD

Last edited by Sam82MB240D; 06-03-2010 at 10:20 AM.
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  #8  
Old 06-03-2010, 11:38 AM
JB3 JB3 is offline
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great!

did you order up 6 of them? I would get all the bushings as well. No sense in replacing only one and having this happen later and it be worse, and the newer clips are way more secure.

You kind of lucked out that the Reverse lever popped off instead of 1-2 or 3-4. Lets say the rod pops off on 2, and you happily try and shift into 3 while the transmission is still engaged in 2. Kaboom!
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  #9  
Old 06-03-2010, 10:19 PM
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Quote:
Originally Posted by dropnosky View Post
great!

did you order up 6 of them? I would get all the bushings as well. No sense in replacing only one and having this happen later and it be worse, and the newer clips are way more secure.

You kind of lucked out that the Reverse lever popped off instead of 1-2 or 3-4. Lets say the rod pops off on 2, and you happily try and shift into 3 while the transmission is still engaged in 2. Kaboom!
I was thinking that this senario with old worn parts is worth including the linkage condition check once a year as part of routine maintenance on the four speed units. Although there have been no members reporting destruction of their manual transmissions. These cars after all are more than twenty five years old.
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  #10  
Old 06-04-2010, 10:18 AM
JB3 JB3 is offline
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Well, let me retract what I said, cause that may not be entirely accurate and sounds scary!

ive only heard of one guy on another forum telling me that had a gear come out the side of the case because it tried to be in two gears at the same time.
I tried to buy it off him, but the deal fell through, I would love to see it though.

Thats the only reason I mention it, otherwise, until I heard that, I had always been under the impression that it was physically impossible to actually do that with the internal detent interlock of these transmissions. at least with 1-2 and 3-4, which have a triangular ball check device directly between them to prevent that kind of thing.

By internal design, you should not be able to move those two external levers if one is already engaged. You also really should not be able to move the reverse lever, its connected with a steel fork to the other mechanisms.

If there was some other internal damage, then maybe it could happen. The weakest internal point in my opinion would be the cast aluminum levers for the synchro mechanisms, maybe if it were cracked or if the fork had popped off between reverse and the other two levers, then conceivably something catastrophic could happen.

It would be unlikely and would have to be a chain of events, but anything can happen I guess. I say this speaking as someone who managed to kiss reverse while moving forward in a ford escort and blew the reverse gear through the case and bell housing. Whoops
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  #11  
Old 06-04-2010, 10:27 AM
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I too would replace all the bushings, not so much on the clips but if they are cheap why not.

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