I am going to do a 4speed swap for dubadxx. We will be taking the 4speed from his euro 83 and putting it in his US 82 240D. The parts car is complete and I will do the swap with the cars parked effectively next to one another, so it should be pretty straight forward. I intend to take some pictures to document it for the community, lots of explanations I've read that were very helpful, but not a ton of pictures so I'll try to add some.

So, what new parts should we do during the swap?

Flex discs
Driveshaft Carrier
Clutch Kit

Were the things I thought were important. The parts car actually drove really nice the clutch felt fine, but it seems like a waste to not just do a clutch kit while the trans is out of the car. The hydraulics feel really good, so the intention was to just re-use those.

Are any of the bolts like the flywheel bolts 1 time use?

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68 280SL - 70 280SL - 70 300SEL 3.5 - 72 350SL - 72 280SEL 4.5 - 72 220 - 72 220D - 73 450SL - 84 230GE - 87 200TD - 90 190E 2.0 - 03 G500

Nissan GTR - Nissan Skyline GTS25T - Toyota GTFour - Rover Mini - Toyota Land Cruiser HJ60 - Cadillac Eldorado - BMW E30 - BMW 135i

Fun project, I did it to the 85 300D.

I would use new FW Bolts
New Slave Cylinder
New Master Cylinder
Replace the Bushings on the Shift Rods, if worn

It is a PITA to replace the MC and Slave as it is and get it bled. would be a shame to install the used ones and have a failure a short while later.

We are all trying to save money where we can, but still....


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

Yeah definitely use new flywheel bolts. Also, I would consider using new throwout/pilot bearings

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1982 300D Turbodiesel, daily driver. Mods so far: Fram 8038 paper filter, 4 brake light mod, Gen II w126 (front) rotors/calipers, boost turned up to 12lbs, non-egr manifolds, water/methanol injection, 4-speed manual
1980 300SD Turbodiesel, project car, nearly ready to hit the street

1974 240D, New paint

I'm getting ready to compile my shopping list for this project. DieselPaul will pick up the parts car this weekend, and as soon as I get parts we'll begin the swap. Looks like I can get most things from PeachParts. So far everything looks pretty affordable.

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'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 recently did an auto to manual swap on a W201. The clutch kit is not cheap IMHO. The used clutch and PP appeared to be in good shape to me and weren't acting up in the donor vehicle. I opted to take the clutch disc to the local clutch shop where they replaced the clutch materal for $50. Used the belt sander and a fine grit belt to remove the glazing from the PP and flywheel. Have been happy with the results so far....only time will tell.

Good luck!

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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.

I was refering to the Slave Cylinder and MC.

The Clutch Disk I installed (Sachs) I had to replace after 22K miles. I pulled the 4-spd out for another problem (Long story) and when I was putting it back in, the shaft wouldn`t go into the Pilot Bearing. I kept hitting something. the bearing came out when I pulled the trans. so removed the PP and Disk and hears something rattle. 2 of the 6 springs (Big ones) each had a broken coil.

So Iam wondering if replacing the Clutch lining and still using the old springs etc... will eventually cause a problem down the road? not saying you will or you were wrong in your decision to do it. but a new Disk was $148......more now I suspect

I called Roy and asked why that happened, and he really didn`t have an answer, but had seen it happen quite a few times in his experience.

Don`t know why the dang things cost so much.


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 had this problem when I removed my transmission (another long story) My clutch and everything was fine... but for some reason the pilot bearing came out of the crank and got stuck behind the clutch disc. I had to take it all apart and tap the bearing back into the crank. Put a little loctite on the outside of the bearing that time. hopefully it stays in there until it needs to be changed.

Put loctite on everything when you do your swap. I found that 2 of the bolts holding my transmission in were finger tight when I went to take the trans out

Moral of the story, Loctite everything!

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