I just picked up a nice clean pretty much rust free '82 240D with the auto trans. I have an '83 Euro 240D with 4spd. The automatic has all the related vacuum issues, harsh shifts, stays in 2nd forever as well as 3rd. Doesn't start in P, and won't hold the car in P. The '83 has an excellent engine and 4sp trans, but the drivers side floor is completely rusted out and the seat is falling through!
I would obviously like to swap the trans into the '82, and maybe the engine as well. The 82 has 239k, the 83 235k. I really don't want to mess with all the trouble shooting involved with the automatic (i went thru all that with my 1st diesel, an 83 300td). Does anyone have any idea of the cost involved with the trans swap? I am not going to attempt this job myself and will leave it to my trusted independent mechanic.
I will be parting out what is left of the '83, by the way.

Since you have both cars next to each other it shouldnt be more than maybe 6-8 hours for swapping and any time for bleeding the clutch and trouble shooting.

For all we know your mech can probably do it in 4.

I have done such swaps, and I would NEVER do another without the donor car within short walking distance of the recipient and preferably close by inside the shop. Trying to do such a swap without the donor car nearby will always result in extra trips after parts that you never dreamed you would need.

Given that you have both cars, decide what you want to swap out and absolutely go for it.

My $0.02,

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2001 SLK 320 six speed manual
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You could do that swap in your sleep. It is a straight forward swap, you have all the parts, just move them from the 83 over to the 82. If I was doing it, it would be a good time to replace the clutch components since it will be out on the ground in front of you. also replace the center support bearing on the drive line, and the Flex Disks.

Adding in the mechanics time and mark up for any parts, you could see a good $1000 going into this project.

When you part out the 83, save everything you can (that`s not rusted out).
your 82 has the 17 gal plastic fuel tank, if the 83 Euro has the 21 gal tank, swap it over. The plastic tanks are known to leak.

Sounds like a fun project, where are you located?

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

Sounds like a great project. I have thought about doing the same to my 240D as well but never seem to find the time.

By all means swap engine and trans as a unit; doing so will obviate the need to rematch the imbalance of the flywheel.

I could do the trans in 3hrs or less. The pedal cluster would be another hour.

__________________
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1995 E420 Schwarz
1995 E300 Weiss
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#1991 300D Nearly Perfect
#1994 E320 Cabriolet
#1995 E320 Touring
#1985 300D Sedan
OBK #42

I did the swap on my 240D in 1999 - best thing I ever did to that car. I guess I should say I had someone do it for me when my auto transmission went south. Total cost for parts and labor was about $1400 then. I had no parts car and had to buy everything. I don't remember a lot about it, but I did save a message I wrote about it if you're interested.

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Len
'59 220S Cabriolet-SOLD and living happily in Malta
'83 240D 351,500 miles original owner-SOLD
'88 560SL 41,000 miles - totaled and parted out
https://sites.google.com/site/mercedesstuff/home
'99 E300 turbo 227,500 miles
'03 SLK320 40,000 miles - gave to my daughter
'14 Smart electric coupe 28,500 miles
'14 Smart electric cabriolet 28,500 miles
'15 Smart electric coupe 28,000 miles

One of the local Benz authorities quoted between 12 - 20 hrs labor! They are very excellent and thorough, but that seems a little high, esp at $92/hr. I can understand their need for perfection and quality of work, but I just need someone to slap the 4sp into the '82. I don't expect a guarantee or warranty, unless new parts are involved.
If I had an enclosed space with a lift, I'd break down and do it myself. Now I'm considering getting the bugs figured out with the auto trans, if I can't find someone to do the swap. But that manual sure is sweet, and the engine it's paired with runs better than the '82. Anyone know any gurus in the SW Ohio, NKy area? Even Lexington, Louisville, Columbus.

20 hrs for a shop to do it? sounds like they will be milking it.
Now I could see 20 hrs with me doing it for myself, as I would be cleaning, replacing things as I went along.

All you really need is a couple jack stands for the front, or run the front up on a couple ramps, and then raise the rear for clearance while being under the car. just make sure it is secure and stable.

My 85 rear wheels are setting in 2 steel rims, park brake on and front setting on jack stands.

Start looking on CL for a good used engine hoist, (I found a almost new one for $65) and a load leveler.

Drop the exhaust, remove the Drive line, mark the 2 sections first in case they seperate.

Remove the 3 shift rods to the trans and under the shifter. disconnect the clutch hyd line. disconnect the pwr steering hoses, fuel lines and electrical harnesses. pull the radiator and ac condensor. cut the radiator X mount so the eng & trans don`t have to be lifted so high. (do not do this to the recieving car).
remove ground strap. remove the two motor mount bolts, trans X mount.
You may also have the "T" mount under the engine.

remove the ashtray, the 2 phillip screws, lift out the ash tray frame. slide the shifter wood or plastic plate to the rear so it clears the plastic pin at the rear. lift up and unplug any switch plugs.
then remove the 4 10mm bolts that hold the shifter to the body. there will be the reverse switch to unscrew. the plug for it is above the carpeted panel above the drivers knee.

Renove the under dash panel on drivers side.
Remove the carpet, and under the clutch peddle will be the clutch line to the master cylinder. remove it and the rubber supply hose from the brake reservor.

Remove the clip and pin where the brake booster rod attaches to the brake peddle lever. remove the plug to the brake light switch.
remove the 4 13mm nuts that bolt the brake booster and the clutch/brake assy together. the peddle assy will be hanging on a hook, will take some wiggling to free it.

Might be a couple other goodies I forgot.

Removing the eng and auto trans will be similar.

Hope this helps. probably getting cold where you are, hope you have a garage.

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

X2, 12-20 hours is outrageous. Better cross that shop off the list.

if they know their stuff, then they know dam well that with two running 240s directly at hand provided by you, the job is straight plug and play. Can't get much easier than a 240, and on top of that, can't get much easier than the way you are going about it. They could get it done in a morning, especially with a lift and a transmission jack.

That quote is a gouge and a half.

I wouldn't even bother with removing the engine, the whole job can be done from underneath with jackstands with primitive tools, and the bestpart is that the 4-speed is preposterously light compared to other transmissions. Like 50-70 lbs. I've done this a number of times and didn't even bother with a tranny jack or anything, just pick up the gearbox and install.
(Different story with the automatic, that will require a jack)

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I think I've decided to swap the entire engine and transmission. the engine in the '82 has more miles, leaks oil,is difficult to start, smokes pretty bad and has all that vacuum stuff connected to it. miraculously, the ac works! the engine in my'83 4spd has had the valves adjusted, runs smoothly and smokes very little,and has only 5k fewer miles.
has anyone done this swap and does anyone want to do it for me?r recommend anyone in the greater Cincinnati area? I don't have the space inside or a lift or engine hoist.
any suggestions?

__________________
'82 240D automatic to manual (sold)
'84 300D (sold)
'12 MINI CooperS Coupe
'71 Triumph Stag
'76 MGB
'08 BMW 535XI wagon
'12 VW Golf TDI

I did a similar swap on a 190D. It truly is quite simple compared to many other makes, the cars are made to accept either components, and are simple and easy to work on. Just remove the parts you need from the donor first, so as to teach you, then youll know what needs to come out of the recipient.

I also second new clutch hydraulics, as well as new clutch hard parts. Then your starting off fresh. Besides, you have to remove them to swap them, the labor is more than half the cost.

I would help you do the swap if we were a couple thousand miles closer.
Too cold and rainy here to do anything out side.
and probably snow up to your @@@ right now in your area.



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

I am currently doing almost the same swap with Greazzer. his euro 300 5speed is going in my 240, and he's driving away this weekend.
it took us about 2 hours with 4 guys to get the drivetrain and shifter out of the rusted heap of a donor car. *I used a chop saw to remove the upper radiator support.
that's 8 shop hours right there. (likely it took a tad longer, He arrived at 9 am and I left at 12:20, but we were not wrenching the entire time.)
I have a shop floor to pull the drive train into, and Greazzer will be pulling the rest of the stuff he needs in the car this week.
getting it back in, will be slower, and caution is needed to do it right. figure 4 hours. you'll be replacing several items like flex discs etc. that'll slow you down.
keep in mind, shop owners charge for each mechanic that is pulling things. if he's got one guy pulling the trans stuff, one guy pulling the drive shaft stuff, one guy doing the exhaust, one guy doing the cooling system, one guy taking the motor mounts loose, all that time gets added up.
I can easily see 20 hours of billable shop time. and yes, I can see them getting the car done in 6 hours total time invested.

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John HAUL AWAY, OR CRUSHED CARS!!! HELP ME keep the cars out of the crusher! A/C Thread
"as I ride with my a/c on... I have fond memories of sweaty oily saturdays and spewing R12 into the air. THANKS for all you do!

My drivers:
1987 190D 2.5Turbo
1987 560SL convertible
1987 190D 2.5-5SPEED!!!

1987 300TD
2005 Dodge Sprinter 2500 158"WB
1994GMC 2500 6.5Turbo truck... I had to put the ladder somewhere!