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#1
10-12-2012, 01:10 AM
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Drive shaft tore off! flex joint disaster.
My girlfriend was driving her '78 240D and the drive shaft tore off the manual transmission at about 30 mph. It ripped two shift rods off the shift linkage broke the spedo cable and bend the cross member a little. That's all I could see so far until I get it jacked up. The tail shaft and rear housing seemed ok.
There was no noise or anything to warn us something was wrong. I didn't know that those joints could just fail like that but I do now. I think I can fix it for her if I can find new shift linkage rods. Can anyone tell me where I can get a set of shift linkage rods for a resonable price? Thanks, T. 
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#2
10-12-2012, 01:17 AM
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Pictures please
Here are links that cover the issue.
Bad flex disk driving home Bad flex disk driving home - PeachParts Mercedes ShopForum Bad Flex Disc Bad Flex Disc - PeachParts Mercedes ShopForum Weekend Wrenching (a great picture of a bad flex disc) http://www.peachparts.com/shopforum/showthread.php?t=216701 The Death of a Flex Disc ... did I kill my 240D? The Death of a Flex Disc ... did I kill my 240D? - PeachParts Mercedes ShopForum What happens when you ignore that "little" driveline vibration! What happens when you ignore that "little" driveline vibration! - PeachParts Mercedes ShopForum Pay attention to your car! Pay attention to your car! Flex Disc Orientation, safety and durability issue. Flex Disc Orientation, safety and durability issue. - PeachParts Mercedes ShopForum If your W123 is shaking down the highway. . . If your W123 is shaking down the highway. . . - PeachParts Mercedes ShopForum Correct way to install front driveshaft guibo? (FLEX DISC) Correct way to install front driveshaft guibo? - PeachParts Mercedes ShopForum .
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ASE Master Mechanic https://whunter.carrd.co/ Prototype R&D/testing: Thermal & Aerodynamic System Engineering (TASE) Senior vehicle instrumentation technician. Noise Vibration and Harshness (NVH). Dynamometer. Heat exchanger durability. HV-A/C Climate Control. Vehicle build. Fleet Durability Technical Quality Auditor. Automotive Technical Writer 1985 300SD 1983 300D 2003 Volvo V70 https://www.boldegoist.com/
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#3
10-12-2012, 01:29 AM
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More data needed
Quote:
* Driver side transmission lever arms area. * Any damage to the bottom of the main shifter assembly. * Drive shaft damage. * Drive shaft carrier bearing BOOT damage. .
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ASE Master Mechanic https://whunter.carrd.co/ Prototype R&D/testing: Thermal & Aerodynamic System Engineering (TASE) Senior vehicle instrumentation technician. Noise Vibration and Harshness (NVH). Dynamometer. Heat exchanger durability. HV-A/C Climate Control. Vehicle build. Fleet Durability Technical Quality Auditor. Automotive Technical Writer 1985 300SD 1983 300D 2003 Volvo V70 https://www.boldegoist.com/
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#4
10-12-2012, 01:59 AM
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Can I remove the shifter out the top to inspect it?
Tonight, I found one shifter rod on the side of the road where it all happend. I don't know how bent it is and the yoke is busted off the end - but at least I found one. I will get some pictures when I get the car jacked up. Thanks! Treven
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#5
10-12-2012, 02:16 AM
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Here is another bad disk picture.
Worst flex disc competition.... where are you located on the central coast? 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
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#6
10-12-2012, 02:54 PM
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Charlie,
I'm in Santa Cruz near Kellys Bakery. I have an '82 Datsun King cab diesel too!! Let's get together sometime. I'll give older mecedes more room on the freeway in the future! I bet lots of them out there have not been inspected. Would have been nice if Mercedes had put a driveshaft loop under there. Beter yet would have been a normal U joint.
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#7
10-12-2012, 03:25 PM
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Mine is not real bad but has the telltale cracks.
With an Auto Trans and my bad Eyes it was hard to inspect the one up Front without dropping the bolted up Cross Member so there is a lot of room to look at it. However, I knew the rear Disc was cracked so they were both getting replaced anyway. Both had cracks. Don't forget to check the Bushings on each end that center them.
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84 300D, 82 Volvo 244Gl Diesel
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#8
10-12-2012, 04:33 PM
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I hope they come with new bushings 'cause I'm pretty sure those are all in the ditch on the side of the road.
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#10
10-12-2012, 07:41 PM
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Quote:
It does not come with the Flex Discs Kit. There is one pressed into each end of the Drive Shaft. The good ones cost around $60 the aftermarket ones like URO type ones around $20. I did not need to change mine but they are soupposed to be packed inside with Grease. Mine were dry and needed to be re-packed. If the Drive Shaft Bushing is worn off center or damaged I am guessing it should be replaced. The Pins that stick into Bushing End that is not pressed into the Drive Shaft also ought to be inspected.
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84 300D, 82 Volvo 244Gl Diesel
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#11
10-12-2012, 10:36 PM
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Here are a couple of pictures if they work:
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#12
10-12-2012, 10:40 PM
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One of the ears on the transmission flange is a little bent. The center seems to run true.
I think I can straighten that cold.... The shift rods are bent and broken. The cross member is a little bent up but if removed, can probably be hammered straight. The shifter levers sticking down into the tunnlel are bent a little but should straighten The tail housing casting isn't broken. Spedo cable housing wrecked. Hopfully the transmission gears didn't get hurt by the violent jerks on the shift rods. Last edited by chevy43; 10-13-2012 at 01:49 AM.
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#13
10-13-2012, 12:03 AM
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I just checked on the Pick and Pull webb site and these are the only 240D`s in the yards.
Pick-n-Pull » Check Inventory Doesn`t tell you if it is an auto or manual trans though. I know 2 in the Windsor yard are manual form another member that was there. I know W123 77 to 80 use the 2 piece (seperate bell Housing) Iron Box transmission like your 78 uses. not sure of the 81, but know 82 & 83 use the one piece Aluminum trans. the shift rods from this trans will not work on the Iron Box trans. I do have a trans X mount and the shift rods for the older trans. Does anyone know if the Tri Flange from an automatic (Diesel) will work on a manual trans? are the splines the same? Good thing she was only going 30mph when it came apart, could have done some severe damage if going 65 on the FW. I had to look up kelly`s Bakery to see where it is, I don`t go on that side of town very often. generaly get as far as Costco. 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
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#15
10-13-2012, 04:01 AM
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Wow!
Thank you for your reasearch and help. Any advice on removing the drive flange off the transmission? The nut looks special.
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