I'm fishing up a 5-speed conversion on a 1983 300 turbo W123, I only get to work on the car a couple of weeks per year when I visit my dad in CA, I am on year 3 and almost done! (5-speed was pulled from a euro-spec 240d)

last year I put the engine and trans together, put them both in the car, got the engine running, then left, nothing else hooked up. After reviewing some old posts on this forum about clutches I'm concerned that I may have bought and installed the wrong stuff. The flywheel I used was from the 240, I cannot remember which throw-out bearing I installed but the clutch disk and pressure plate were NEW and for a 240. I hear it might be possible that this disk/pressure plate combo may not be well suited for the power that the turbo 5 cyl. will make. And what about the 240 flywheel, ok? I have about a week to go to get this car drivable, but If I am going to need to change parts I'd rather do it now before I get it all buttoned up.


Clutch advise????


Thank you!!!

The 240D clutch and pressure plate will be just fine. the 300D engine produces 123hp and the 240 67hp.
The 240D FW will also work, there have been a lot of 4 spd swaps done over the years using to 240 FW.

Iam using the 240 FW in my 85 300D. in 1st and 2nd I can run it to over 3000 rpm`s w/o any vibrations. 3rd gear pretty much the same.
4th gear as long as I stay over 29 - 3000rpm`s she is smooth, soon as I drop down to say 2800 or so, I need to down shift. I feel some vibs. might have something to do with using the 2:88 Diff and being geared high.
some use the 3:07 and say it works better, I think that is what you have in your 83.

I know on the clutch parts, there are 2 different throw out bearings, and the slave too I believe, all depending on the chassis number of the 240 you got the 4 spd from. Iam usung the all one piece trans so uses the later parts. I believe if you have the old iron box, then it is the earlier parts.

I just reread this, I was thinking 4 spd when I typed this, DUH.... It`s 12:30am.

You have a 5 spd, you lucky guy. that is the Holy Grail of transmissions. I have the other one, the Holy grail of flywheels, the 300D FW. looked for 4 yrs for one of them. that is going in next.

You still should be ok with the 240FW and clutch.

Did you work out the transmission X mount problem? where are you in Ca?



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

We are advised to NOT judge ALL Muslims by the actions of a few lunatics, but we are encouraged to judge ALL gun owners by the actions of a few lunatics. Funny how that works

Charlie is right!

Congrats on the five speed and the conversion.

__________________
[SIGPIC] Diesel loving autocrossing grandpa Architect. 08 Dodge 3/4 ton with Cummins & six speed; I have had about 35 benzes. I have a 39 Studebaker Coupe Express pickup in which I have had installed a 617 turbo and a five speed manual.[SIGPIC]

..I also have a 427 Cobra replica with an aluminum chassis.

It sounds like the only thing you could have made a mistake on was the throw out bearing, which you will find out about when you fire up the car. I used the wrong one in the 79 when I swapped a 5 spd tranniy from a Euro 82 240D into my 79 240D. I pulled the tranny twice before I figured it out If your clutch works you got it right

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1985 Euro 240D 5 spd 140K
1979 240D 5 spd, 40K on engine rebuild
1994 Dodge/Cummins, 5 spd, 121K
1964 Allice Chalmers D15 tractor
2014 Kubota L3800 tractor
1964 VW bug

"Lifes too short to drive a boring car"

Hi Charlie,

The 5-spd. trans is 1.25" longer than the 4-spd. I haven't had much time to spend on it yet, but if you have some mounts around that you would mind measuring I'd really appreciate it. The trans mount is bolted to the car with 4 bolts, on my car there are 8 possible mount holes (possibly for other engine/trans combos) my car is set up to use the rear 4 bolts for the trans mount, to use any other of the 8 holes one would need a different mount, as the bolt pattern is wider.

ANYHOW! using the last 4 bolt holes, if you look at the forward pair, the center of my trans mount hole (on the trans) is 1" forward of this pair of mount holes.

does that make sense?

i can send a pic tomorrow and will be easier to understand.

I'm In Fresno visiting my parents, one of the worst places in the US, no kidding.

Thanks again.

Kevin

The 240D automatic cross mount, uses the 2nd and 3rd hole from the rear, or last hole.

Looks like from the center of one of the 2 bolt that bolts the transmission to this plate, there is 1 5/8in to the rear of the slot. there are 2 slots, one for each bolt for forward/rear adjustment.

If that is not enough adjustment for your 5 spd, you might be able to make the slot another 1/2 in to the rear.

Your 83 and my 85 300D are exactly the same. a w123 chassis.

Fresno, HMMM that is a desolate place isn`t it, gets pretty warm there in the summer. a plus, at least you are close to Buck Owens Country palace in Bakersfield.

Charlie

__________________
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

We are advised to NOT judge ALL Muslims by the actions of a few lunatics, but we are encouraged to judge ALL gun owners by the actions of a few lunatics. Funny how that works