Thanks guys. I am still smiling, and it was a great ride into work this morning in my new car.

The dimensions on the pilot bushing we made of bronze were:

OD: 1.366 inches
ID: .591 inches

The ID felt a little tight on the input shaft, so I cleaned the input shaft and stuffed some scotchbrite in the bushing ID and turned until the fit was perfect on the input shaft.

The OD was spot on and went in like a press fit should -- a slightly smaller socket and a handful of good hammer blows got it right in.

The length was more or less not a critical dimension to us, we made it longer than the stock sealed bearing by about 50% and I drove it farther into the crank until the outside edge was flush with the end of the taper on the crank. See attached photo.

Charlie, yes, the auto trans was heavy. I balanced it on a floor jack with a piece of wood between the trans and the jack. It was less then ideal, but I moved the jack around until I found the balance point and then did not dilly-dally in getting it closer to the ground in a controlled fashion.

I also realized this morning that I put the wrong kind of oil in the trans -- I went to autozone and happily bought 75w lucas trans and diff oil, which shifted fine last night but was quite stiff this am. Now I have read the threads and have ordered redline MTL. Hopefully haven't torn anything up, but I think it'll be alright as the shifting was fine if not a little stiff.

-Dan

Attached Thumbnails

 

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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...

Thank you for the bushing info. I don`t think this has been posted before.

As far as the trans oil, the heavier oil slows down the gears and makes it stiff between shifts. I originally used Amsoil 80w 90 gear lube thinking the high milange and maybe wear, it should be fine, but made the shifting stiff and some grinding between shifts.

Changed it Amsoil ATF, and it shifts like butter.

I have been using their gear lube in the 5-spd in my 82 Datsun PU for better than 400K miles and it shifts nice and smooth, but the MB manuals are different.

Use what ever flavor you like, I just mentioned what I use.


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

no worries,you did not torn anything,...when you say stiff..do you mean stiff on hand while shifting or stiff while letting clutch pedal up?

also if you did not drive manual before .. dont expect automatic behaviour
it has to be stiff in some way ... loose manuals over here we avoid as it
is sign of "inner" play ....

cheers
ChO

.

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w126 500SEC gen II euro, powered by OM617 turbo stolen from 84 300SD 2.88 diff,EGR blinded
next wish/project: w114 coupe OM603 powered

I'm very happy with the 4spd swap in my TD. No vibration at all, but does have a slight buzz when lugging 3rd/4th gear, not really a vibration though, car is smooth running and nice on highway.

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82 MB 300TD, 87 Audi 4000TQ, 05 Audi A4 avant 1.8T 6spd (Wifes), 63 356C, Samurai VW 1.6TD, 71 NSU 1200C, 71 Toyota Hilux, tractors and junk

Hey Cho ... Just stiff shifting gears when it was 30-something outside this morning. I'll get more appropriate oil in it asap. I agree -- we don't want "non-stiff" manual transmissions!

-Dan

__________________
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...

Sounds like you answered your own question about whether or not people like their manual tranny diesels!

Yeah, it only took 42 posts and 50 days to find out. he will be walking around with that silly grin for weeks on end....


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

I've read multiple online posts from people who have put a 240d manual transmission in a 300d. I have a decent 83' 4 speed 240d and would like to install a 300d engine in it. Has anyone done this? How much more difficult/expensive to go that route?
Thanks.

If you did that I would suggest the NA 300 if you can find one.

Someone mentioned RLeo and his four speed Wagon Marlene... he got out of MB totally... I believe both his children have children....so he is a busy Grandfather out at the farm...

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1980 240d ,

chain elongation, cam marks reference:
http://www.peachparts.com/shopforum/diesel-discussion/10414-help-i-need-check-stretch.html

http://www.peachparts.com/shopforum/diesel-discussion/305365-9-degrees-chain-stretch.html

evap fin cleaning:

http://www.peachparts.com/shopforum/diesel-discussion/156207-photo-step-step-post-showing-w123-evaporator-removal-1983-240d-1982-300td.html?highlight=evaporator

A/C thread

http://www.peachparts.com/shopforum/diesel-discussion/297462-c-recommendations-mb-vehicles.html

I've done one at least and owned one done by someone else. And built up a 300 NA for use in a 240. They all were good but the one with the actual 38# 300 flywheel was the sweetest.

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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.

I'm happy with mine (with the light flywheel) but it is race-only and may not be a good data point for a street driven car.

Dan

I'm still driving the same car, with the same 240D flywheel, that I posted about in 2013. I did manage to fail a clutch disk, but the replacement is holding up. I'd rather be driving a 911, or an M3, but I haven't found money in the budget for one of those, so the turbo/manual 300D is sticking around for a while (as in indefinitely) longer. I put more miles on my bike as it is, so barring something catastrophic, I may be keeping this car another decade or more.

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Whoever said there's nothing more expensive than a cheap Mercedes never had a cheap Jaguar.

83 300D Turbo with manual conversion, early W126 vented front rotors and H4 headlights 400,xxx miles
08 Suzuki GSX-R600 M4 Slip-on 22,xxx miles
88 Jaguar XJS V12 94,xxx miles. Work in progress.