So I swapped an engine (with a manual transmission from I think an 80 300d) from a 1980 240d manual into an 82 240d auto chassis. Everything seemed to line up and got the motor and anti vibration mounts bolted in, the transmission mount is not bolted onto the frame yet so I have some play. I went to install the front and rear drive shafts (front from the manual 80 rear from the automatic 82), the rear seemed to line up okay, as did the center mount, but the front drive shaft will only fit into the front flex disk when I pull it forward from the center support bracket so that an inch of the threads of the rear drive shaft coupling are showing. If I have the front drive shaft snug against the retainer clip and dust cover of the center support mount, the front of the front drive shaft won't reach into the transmission and flex disk. I assume this isn't right, can anyone help?

sounds like you need the front shaft from a 78-81 300D...

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My drivers:
1987 190D 2.5Turbo
1987 190D 2.5Turbo
1987 190D 2.5-5SPEED!!!

1987 300TD
1987 300TD
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X2

If you dont wish to do that you could always cut a piece out of the car to shorten its length (being silly).

Best not to try & lengthen a shaft, it will be too hard to balance.

Make sure before you get another shaft that you have measured what its length needs to be & the one you are going to get is the correct length.


Good luck !!

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1967 230-6 auto parts car. rust bucket.
1980 300D now parts car 800k miles
1984 300D 500k miles
1987 250td 160k miles English import
2001 jeep turbo diesel 130k miles
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1968 Ford F750 truck. 6-354 diesel conversion.
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Heh, I thought of installing two flex disks with longer bolts but it wouldn't be the same. Phew, the shop that got me the transmission I guess was unaware of the minor difference of less than an inch in length . I assumed it was the same even though it said "300D" in chalk on the side. Fit the same on the engine too. Thanks for the help guys
.

I have not checked the local parts places but according to this old thread: W123 300D Manual drive shaft

The w123 300d manual front driveshaft is significantly shorter than mine (by about 5 inches). This might make sense because of the 5 cylinder being longer. Found this for reference:

http://www.europeantransmissions.com/Application.htm

Seems I may have a 722.118 transmission when I should have a 722.117. Anyone have experience that can confirm that a w123 300d manual won't fit a w123 240d om616?

All 4speeds are the same length. If I read you correctly you have a 4 spd + om616. Finding the correct DS should be fairly easy. Try car-part.com. The om617 + 4spd is a hard driveshaft to find.

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Just the info I needed, thanks winmutt. Yes it is the 2.4L diesel the om616.912 and a 4 speed manual.

Wow that is baffling.
Facts: The euro 300d front driveshaft with a manual is 20.5 inches
300d with automatic had a 15.5 inch driveshaft (will double check as this is from memory)
I measured my 1979 w123 240d automatic to have a 19.5 inch front driveshaft.
My w115 240d with a manual transmission had a 24" front driveshaft.

So assuming the auto transmissions were the same length between 240 and 300 then the 5 cylinder puts everything 4" closer to the rear. Which would seem to call for a 24.5" driveshaft. But the 26" is too short here.

Just to clarify, when the front shaft is put forward to where it can be bolted to the flex disc it falls off the rear where it was on the splines? Or is it just exposing some of the splines?

--Fourthbean

I believe it should expose some splines, maybe 1/4 of an inch? There is a dust cap that fits on the end of the front shaft that covers these splines, yours probably disintegrated away. I believe you need this 1/4 inch so you can install the shaft, othewise it would be too tight to fit in. Let's hear from the experts though if this is correct.

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1983 300TD - 202k with 5 speed Getrag conversion

There are 3 1/2 inches of splines, so an inch of exposure should be fine. you will need some wiggle room the R&R the shaft.

you also will need this boot to cover and protect the splines.


Drive Shaft Coupling Boot MBZ056479 from Allpartsexpress. $4.16

Charlie

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there were three HP ratings on the OM616...

1) Not much power
2) Even less power
3) Not nearly enough power!! 240D w/auto

Anyone that thinks a 240D is slow drives too fast.

80 240D Naturally Exasperated, 4-Spd 388k DD 150mph spedo 3:58 Diff

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