In a few weeks I plan to swap a 5 speed from a 1984 2.3L W201 into my 1987 2.5L 190D Turbo. I also plan to swap the differential (should be a 3.27 in the donor according to the chart - post#5) at a later date. I have the full donor car with all linkages, etc.

I have researched the forum and found some great information on the swap, however with it being my first one I would like to submit to you all my parts list to see if I'm missing anything:

1. Flywheel bolts (plan to use donor flywheel, haven't seen anything saying that would cause problems)
2. Throwout bearing
3. Transmission Mount
4. Clutch Plate
5. Flex discs
6. Center Bearing / carrier (depending on condition)

It seems most have used the front section of the donor driveshaft but left the rear in place on the recipient car. Since I intend to eventually swap differentials I plan to swap both sections together.

Any advice would appreciated.

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Spencer

87 2.5L 190D Turbo 5-speed - 102k (Daily Driver)
82 300D Turbo - 145k - Light Ivory (near mint)

Gone: 85 300D Federal - mileage unknown

If you search online, there's an entire write-up with pics on a 5-speed swap for a w124 (should be almost the same for you). Its on mymbonline, and I believe done by AOK Motorsport. Here's the parts list they had:




List of Parts Needed:
103 030 1205 - Single Mass Flywheel
011 250 0903 - Clutch Disc 8.5"
004 250 3104 - Pressure Plate for 8.5" Clutch Disc
912004-008102 - Pressure Plate Screw washers - NOTE: You need six (6) of these
000912-008012 - Pressure plate screws - NOTE: You need six (6) of these
001 250 2415 - Throwout Bearing
115 980 0115 - Pilot Bearing
201 260 23 33 - Shift Linkage 5th/Reverse
201 260 22 33 - Shift Linkage 3rd/4th
201 260 21 33 - Shift Linkage 1st/2nd
000 994 29 60 - Shift Linkage end clips - NOTE: You need six (6) of these
201 540 1568 - Speedometer Cable 1490mm - Note: Some models already have this length of cable. Remove from auto trans and install on 5 speed. They are interchangeable
001 295 6806 - Clutch Master Cylinder
201 290 0311 - Clutch slave cylinder
129 410 0601 - Front Driveshaft for COUPE
124 242 0501 - Transmission mount for 5 speed manual - NOTE: auto and manual use different mounts!
304017-010036 - Bellhousing Bolts - NOTE: You MAY reuse removed bellhousing bolts
304017-010035 - Bellhousing Bolts for starter - NOTE: You need two (2) of these. You MAY reuse bolts.
124 267 0097 - Shifter boot
B6 6 26 8109 - Gearshift Knob with leather boot
124 295 0513 - Clutch Line
203 997 3182 - Hose From Reservoir to Master Cylinder 270mm
124 683 0306 - Shifter Frame for Shift boot to center console wood (5 speed version)
XXX XXX XXXX - Shifter - NOTE: Will need corresponding shifter for particular transmission. They have different shift patterns that the shifter assemblies are designed for
XXX XXX XXXX - Brake Fluid Reservoir - NOTE: The brake fluid reservoirs ON ALL W124 and W201 cars have a nipple on the side of the reservoir. Simply cut off the edge of that nipple and attach your hose to the master cylinder to this nipple.
XXX XXX XXXX - Brake/Clutch Pedal Assembly - NOTE: All W201 and W124 use the same pedals.
NOTE: There are some miscellaneous small parts that are not on the list. This is due to myself not wanting to take the time to find them and write them down. These omitted parts are small clips and attachments that are already used on the attachment parts to the automatic transmission.

Well he didn't list the 12 flywheel mounting bolts which are single use only

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Junqueyardjim
Christianity, if false, is of no importance, and if true, of infinite importance. The only thing it cannot be is moderately important. C.S. Lewis



1983 Mercedes W123 240D 4 Speed 285,000 on the road with a 617 turbo, beautiful butter yellow, license plate # 83 240D INDIANA

2003 Jaguar Type X, AWD. beautiful, good mileage,
Mom's car, but I won't let her drive it!

It looks like a slave cylinder gasket is needed as well. Are the bellhousing bolts typically reused? I know they "may" be used, but I wonder if people have had problems.

__________________
Spencer

87 2.5L 190D Turbo 5-speed - 102k (Daily Driver)
82 300D Turbo - 145k - Light Ivory (near mint)

Gone: 85 300D Federal - mileage unknown

Is the pilot bearing the same OD and ID for all Mercedes motors (both gas and diesel) in this era? If so, does this mean any Mercedes manual tranny will fit any Mercedes motor (bellhousing bolts excluded)?

Since all the 2.5DT's were automatics in both the '87 190's and the 1990-93 300's, will all the crank shafts accept a pilot bearing?

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You can't always get what you want, but if you try sometime you just might find you get what you need.

Does the donor trans have a 1:1 5th gear or overdrive? One would be acceptable to marginal with the 3.27 rear gear and the other wouldn't suit a diesel well at all.

Do I remember correctly that only the 16 valves had the 1 to 1 5th?

__________________
You can't always get what you want, but if you try sometime you just might find you get what you need.

Yes it will

The donor it's an overdrive transmission only the getrag from the 16 valve it's a 1:1 5th gear

Is it the same pilot bearing that fits the 2.3 gassers? Do you know it Mercedes used the same pilot bearing in all their auto applications in this era?

__________________
You can't always get what you want, but if you try sometime you just might find you get what you need.

Yes it's the same pilot bearing used in all 4,5,6, cylinders gas and diesel in this era the changed came when M.B. stared using dual mass flywheels the pilot bearing is no longer in the crankshaft but in the flywheel it's a bigger pilot bearing

Do you happen to know when the bellhousing bolt patterns changed ie. what manual transmissions bolt up to which motors? The 240's 4-speeds mate to the OM617, will a 240 4-speed mate to the W201 motors and will the W201 manual trannys mate to an OM617? How about 90's era gas manual trannys?

__________________
You can't always get what you want, but if you try sometime you just might find you get what you need.

615, 616 and 617 share a bell housing pattern; 601, 602, 603, 604, 605, 606, 102, 103, 104 share a different bell housing pattern. I don't know about older engines and engines with more than 6 cylinders. My guess is 90s 111 MTs share the 104 bell housing but they probably get into the dual mass flywheel situation mentioned above.

Sixto
87 300D

And as an interesting aside, I used the pilot bearing from my old 250 Ferrari in a 240d.

Perfect fit.

The only difference was in the Ferrari there was a snap ring holding in the pilot bearing.

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[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.

RE DS, we have to half and half it because the 603 flange is much larger than the 602. You should be good to do.

Pro tips:
Insert your trans rotated with arms down and then in the last 1/2" or so rotate it to match.
Hookup the clutch slave to the hose before you mount trans.

Be prepared to have a variety of 3/8 and or 1/2 extensions and u joints for the top bolts on the trans. Not sure about 201, but on the 603 i found that ONLY a 3/8 extension would have the clearance to keep the socket on the bolt (with u join of course), a 1/2" extensions would not.

Don't forget to short the neutral cutout switch (purple wire). You may also find that you have a clutch cruse control cutout. Not sure how that wires up.

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