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  #16  
Old 02-06-2013, 09:41 AM
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In an 85 you will need to do some custom pilot bearing work. The diameter in the crank is too large for a standard 240D pilot bearing. Usually requires a spacer or some honing to put a lager size in. '83 and older don't have this issue.
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2010 VW Golf TDI Cheetahhh
2008 GL320 CDI 4matic x2
2006 E320 CDI
1983 200 (Euro 5spd)
1982 300TDT
1981 300D (617.951 swap)
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  #17  
Old 02-06-2013, 09:59 AM
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The 85 crank hole is Smaller than the previous years, this is the problem with using the standard Pilot bearing. there really isn`t a standard size Bearing for the 85 Crank.

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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  #18  
Old 02-06-2013, 10:19 AM
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Thanks for the correction.
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2010 VW Golf TDI Cheetahhh
2008 GL320 CDI 4matic x2
2006 E320 CDI
1983 200 (Euro 5spd)
1982 300TDT
1981 300D (617.951 swap)
1966 200D
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  #19  
Old 02-06-2013, 10:21 AM
Posting since Jan 2000
 
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Posts: 5,326
I have converted a number of cars from automatic to manual over the years with good results, but have never done an MB.

I am hoping that RLeo will weigh in on this thread. I rode in his converted station wagon while he was trying to figure out the resonant vibration. I don't know what he ever came up with.

You might PM him and see what he says about it. He's a really nice guy and I don't think he would mind a PM.

Good luck
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  #20  
Old 02-06-2013, 10:27 AM
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I sourced a 2 pin connector for the reverse light switch from a harness I removed from an '85 parts car which was an auto. The connector isn't unique to manuals.
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  #21  
Old 02-06-2013, 01:19 PM
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Quote:
Originally Posted by w123love View Post
In an 85 you will need to do some custom pilot bearing work. The diameter in the crank is too large for a standard 240D pilot bearing. Usually requires a spacer or some honing to put a lager size in. '83 and older don't have this issue.
Well it is true the hole in the 85 crank is pretty small - tight as heck to put it mildly. I was facing the same problem on my 4 speed switch over. Well I called my friend who had a service shop on the west side of Phoenix. Did a heck of a lot of cltuch and transmission work. So I told him that the problem was about 35 thousands to small on the bore into the crank. He said "freeze it" and stick it in. Put it in a good cold deep freezer over night and tap it in quick when it is nice and cold. If the crank end is cold, warm it up a little with a heat gun, light or propane torch. Then he told me to measure the hole depth. Stick a long socket in the hole to find out how deep it is because you don't want to be beating on a frozen bearing when it can't go any further. So now you know how deep you have to send it, add the width of the bearing to your mark on the socket or extension so you can tell exactly when it bottoms out. And get a top quality bearing! It is not going to be fun to remove it. But the pilot bearing does very light duty and I don't think it will ever be replaced. It only operates as a bearing when your foot is on the clutch. At all other times it is a simple rotating mass.
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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!
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  #22  
Old 02-06-2013, 03:46 PM
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You not going to freeze fit 35 thousandths maybe a few but not 35
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  #23  
Old 02-06-2013, 03:51 PM
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Quote:
Originally Posted by raysorenson View Post
I sourced a 2 pin connector for the reverse light switch from a harness I removed from an '85 parts car which was an auto. The connector isn't unique to manuals.
I will try to take a snappie of my spare 5 speed shifter. The 2 pin deal is much smaller than the common 2 pin deals in the W123's.
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  #24  
Old 02-06-2013, 04:22 PM
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Yeah, it's not just any 2 pin connector.

If you absolutely can't get this connector, you can just extract the right size female pins from a connector and slide them on the switch.

Regarding bearing size, many manual transmissions just used a brass bushing for a pilot bearing. This would be easy to custom machine. I'm using one on my OM617 equipped Landcruiser.
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  #25  
Old 02-06-2013, 06:49 PM
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Quote:
Originally Posted by Styler_Colfax View Post
You not going to freeze fit 35 thousandths maybe a few but not 35
Yes, I do think I gave an incorrect number. Sorry about that. Now one further reflection, I think that the difference is 23 thousandths. Believe me, on a hot summer day it still took a lot of heavy hammer work to get it in there. Still is quite a squeeze, but mine is running well after almost 2 years and 12,000 miles, and my shop owner friend in Phoenix says it will have good service life.
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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!
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  #26  
Old 02-06-2013, 08:54 PM
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Location: Out in the Boonies of Hot, Dry, Dusty, Windy Nevada
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Here is some good thread links.

240D 4spd in 1985 300TD

Need a quick OM617 into a 240D list....

Need Help - Tranny Swap to Manual

Pilot Bearings | StreetPerformance.com

617 FW Info
617 flywheel

Picture of a 240D & 300D FW.
bought a 74 240D this weekend


These threads should clear up a lot of the questions.


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
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  #27  
Old 02-06-2013, 11:00 PM
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Location: Westminster, SC
Posts: 89
Wow, great stuff guys; many, many thanks. Did not know about the pilot bearing challenge on the later cranks or the front-end height issues due to the lighter manual trans. Also not quite sure on the match-balance thing ... is the torque converter not a big part of the rotating mass moreso than the flex plate? Maybe it'll make more sense once I see it myself. Or maybe the TC is neutral.

I held my ground on the $1100 I offered on the donor car and apparently that was not meant to be. But I feel good about that. I'm leaning towards one of the 'kits' on ebay as at least I wouldn't have to do the removal. I was also shocked at the price of new clutch parts, but I guess that's what we pay with these fine machines.

Will keep you all posted. I guess I'll document the job in this thread unless it would be better to start a new one.

Thanks again,

-Dan
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1976 w115 300D 4-speed conversion!!
1985 w123 300TD 4-speed conversion!!

Non-Mercedes old stuff:
1941 Buick Special (Straight 8!)
1946 Luscombe 8a
1947 Willys CJ2a
1950 Chevrolet 4400 dump truck
1954 Chevrolet 3600 3/4 ton
1954 Cessna 195B
1955 John Deere model 40
1991 Ford Taurus SHO
2013 Jetta SportWagen TDI 6-speed (I sold out...
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  #28  
Old 02-07-2013, 12:04 AM
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That is good you held your ground, a deal is a deal.


It surprised me when the front end came up so high. I had just finished the swap, and made a trip from Santa Cruz, Ca to Portland, Or. 740 miles. It made for and interesting drive as it sort of throws out the steering, and the front end wanted to slightly wander.

Replaced the front springs with 240D front springs, dropped the front end down, but is a softer ride. car sits nice, but need to stiffen it up.

I have the engine out for another problem, and have installed a 300TD front Sway Bar, and new Firewall Bushings. this bar is 2mm thicker than the 300D bar. so this should make her ride nicer when I get her back together.

Since you already have a TD, you are all set as far as the Sway Bar.

In this thread is a GTG I went to on this trip. It was held in McMinville, Or. where the Spruce Goose is Hangered. we got our pictures taken under the tail of it. was cool.

NW GTG............June 13, 2009

(click on the picture and it will get larger)

This first & third picture you can see my 85 Silver with the black grill, it sits almost a head light higher than the cars on each side. this is pg 7 and the pictures start on pg 5. some cool pictures of the Goose.

Go down to post #20 and there is some pictures of a front bar swap and the 2 bars side by side. this is Winmutt`s car, and him chewing on the bar.

Big front sway bar

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

Last edited by charmalu; 02-10-2013 at 09:00 PM.
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  #29  
Old 02-10-2013, 05:43 PM
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Join Date: Aug 2011
Location: Westminster, SC
Posts: 89
Committed now...

Conversion parts are hopefully on the way... Decided this weekend to pull the auto trans. In hindsight it wasn't a big deal, but there was a learning curve:

Three feet of good wobble extensions to get the top trans bolts, as I've read here... The top 10mm socket head starter bolt was a real booger: wound up using the wobble extensions and a 3' breaker bar and lo and behold the extensions held and the bolt cracked loose with a loud pow!

I don't think this trans has ever been out -- bolts look new and shiny. 262K miles on this car.

Next is to mark the flex plate and remove for match balancing.

Thanks for all of the help, all...
Attached Thumbnails
300d 4-speed swap: are you happy with it?-image.jpg  
__________________
1976 w115 300D 4-speed conversion!!
1985 w123 300TD 4-speed conversion!!

Non-Mercedes old stuff:
1941 Buick Special (Straight 8!)
1946 Luscombe 8a
1947 Willys CJ2a
1950 Chevrolet 4400 dump truck
1954 Chevrolet 3600 3/4 ton
1954 Cessna 195B
1955 John Deere model 40
1991 Ford Taurus SHO
2013 Jetta SportWagen TDI 6-speed (I sold out...
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  #30  
Old 02-11-2013, 09:27 AM
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Location: Out in the Boonies of Hot, Dry, Dusty, Windy Nevada
Posts: 9,585
I see you are still smiling, It`s a good feeling when you are getting to your goal.

Post a picture when you are bleeding the Clutch.

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
Reply With Quote
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