If you have access to a belt sander and the flywheel is not grooved, then use a fine grit sanding belt to remove the glaze from the flywheel. That's really all that is accomplished (but they don't use a sander) when a machine shop resurfaces a flywheel unless the flywheel is grooved or damaged in some way. Do the same to the pressure plate.

I just came across this tread, I'm about to do the same swap with two of my 300Ds in about a week, very interested in seeing how this turns out for you!

Was the pilot bearing hard to source on eBay? I just picked up a solid 84 300D non turbo euro with a manual trans that was heading to the scrap yard, and want to drop an engine from an automatic car into it.

Best of luck, looks like in a few days you'll have yourself a nice car this summer :)

Yep! I'm excited for it. I just ordered a pilot bearing for a 240d on ebay. It was like $9 bucks. Are you going to make a thread for your swaps?

Have you looked in here for any of your Clutch related parts?



1982 Mercedes-Benz 240D Sedan - Clutch & Flywheel - Page 1

Charlie

While I'm waiting for my pilot bearing to show up, I tried to start it today, without the tranny. Turn the key, nothing. I forgot about the neutral safety switch! How do I rewire that? What do I need to do?

The Neutral Safety Switch and reverse light switch harness goes through a grommet in the transmission tunnel and up to a 4-prong plug on the left side of the center console near where the driver's right knee would be.

The cleanest fix is to get the reverse light harness from a manual 240d. It connects from the shifter to this 4-prong plug to turn on the reverse lights and short the NSS circuit.

If you don't have this or can't get it from the junkyard, you can connect the violet wires to make the starter circuit work.

-Dan

What is the torque for the flywheel??

I tried to install the pilot bearing, but now it's not spinning. Has anyone had problems with the bearing? Any advise? How do I get it back out?

$90 for DS and $35 for fw. YMMV. Where are you located? Update bio/sig

How did you determine that the pilot bearing is not spinning? What part of it is not spinning. Remember that the center part only is what spins. Not impossible to determine if it is spinning, but it is too far in the hole to tell with your finger. Unless you abused it something awful, it should turn well, and unless you have hard evidence it is not turning I wouldn't worry about it. Did you have any difficulty getting it all the way in the bore?

Yes, it wasn't really going into the bore straight, I used a socket and hammer, and it finally went in, but now the center doesn't spin. How far is it supposed to go into the bore?

I dont know if its possible to drive it in too far. I've never had a problem putting one in. There should be a half round (dome shape) piece with a round hole in the top to make sure the bearing stays in the hole. The tranny input shaft goes through the hole and into the bearing.

I installed it, but the inside piece does not spin anymore

You need to be careful when driving in a pilot bearing that the driving socket only contacts the outside of the bearing. If it presses on the inside, it will ruin the bearing. Sounds like that may have happened. To get it out, stuff grease in the hole, then take a dowel or metal rod about the same size as the inside diameter (ID) of the bearing. When you have enough grease in there, put the rod in the ID and tap it with a hammer. The grease will push the bearing out. You may have to add more grease if the rod bottoms out.

As far as flywheel bolt torque goes, look back a few posts on this thread. I posted a copy of the FSM page that tells you all the specs on that. I believe it's 30-40 nM and then an additional 90 degrees. AKA very, very tight. New bolts should be used if the waists are smaller than specified.

-Dan

Attached is a pic of how deep I pressed the pilot bearing in my last conversion -- to the bottom of the chamfer in the bore.

-Dan