My project is coming along I suppose, but slowly. I had trouble getting the pilot bearing out, a couple of days worth of being covered in grease and then quitting. I never got it out, but the bearing finally started to spin! So today im going to try to clean out the grease, and install the flywheel and clutch. Any idea where I could get a clutch aligning tool, besides buying one? I am reusing the clutch I got from PNP, it looked pretty good. Or how can I just align the clutch? Do I have to use the tool?

I also didnt really understand the wiring of the neutral safety switch. Does anyone have a diagram or picture of what they did to theirs? When I was at PNP, I pulled the reverse wiring, so I have that.

On the w124 swap, the neutral safety switch had just 2 wires going to it that I spliced together and no more neutral safety. Just have to be careful to be in neutral or have foot on the clutch whenever I start the engine. I do both.

__________________
CENSORED due to not family friendly words

Did you look at the 2 links I posted in Post#78? there is some pictures of the plug above the carpet. remove plug.

From under car pull the cable and this plug out of the tunnel along with the grommet. this is your NSS you will discard.

Keep the grommet, wash it up, reinstall it and fill the hole with RTV.

Your plug from the reverse switch from the 4-spd shifter will plug into this plug above the carpet.

The 2 purple wires are for the start. the other two are for the reverse lights.


The Clutch alignment tool can be bought from the Auto Supply. It is the same one used for a Chevy 10 spline shaft.


I was taught many years ago to push in the Clutch Peddle each time I started the engine. this way there isn`t the possibility of the transmission being in gear and having the car lurch forward, and injuring someone or something.

Most older car/trucks do not have a natural safety switch.

$20 for a Pilot bearing? wow, they are something like $7.50 here on pelican.

1980 Mercedes-Benz 240D Sedan - Clutch & Flywheel - Page 1


Charlie


Sent from my POS Computer.

__________________
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 torqued the flywheel to 40 ft lbs and then turned each one a little more. I went to autozone and they had a clutch alignment tool in stock for 3$ so i bought that. Now to install the clutch and PP, what should I torque the pressure plate to? After I install that, can I bolt up the tranny? DDD

Make sure you put blue thread locker on...

__________________
http://superturbodiesel.com/images/sig.04.10.jpg
1995 E420 Schwarz
1995 E300 Weiss
#1987 300D Sturmmachine
#1991 300D Nearly Perfect
#1994 E320 Cabriolet
#1995 E320 Touring
#1985 300D Sedan
OBK #42

I didnt put any on the flywheel bolts, but I will on the pressure plate bolts.

A lot of progress today. Installed flywheel, clutch, pressure plate, and then transmission. Did a few small things like installed hydraulic lines. Now all I need to do is NSS, Driveshaft, and shift linkages?

Something weird is going on with the electricity. I had to rewire that switch, because this was an 81, it never had a neutral safety switch, or at least it was different. I had to wire it when I did the swap out of the wagon, and I wired it now.


I attached the plug and now when I hook up the reverse plug from the manual, the Battery and Seat Belt lights on the cluster light up and dont turn off, even with the key out of the ignition, and still I cannot figure out how to start it.

I think my reverse switch is different. People on the forum talk about the plug on one side, and then a 2prong plug that plugs into the shifter, on my reverse wire, the shifter part has a little switch that the shifter pushes in when it is in the reverse gear, and the other end on the wiring has an extra purple wire that I have no idea what it goes to.

I took my driveshaft to 2 driveshaft shops in my area. The first shop told me it would cost 140$ to shorten it 4 inches, but when I started talking about balancing, he didnt want to do the job anymore. The second shop I went to called another company in which they told me for it to be professionally done, it would cost 490$ plus tax, plus I have to ship it out of state, so it would probably be closer to 600$. So i'm kind of stuck. The people who have done this, where are you located? What shops will do this kind of work, and so that it is done correctly.

Ive mailed mine out to these guys with good results-

Powertrain Industries - Springfield :: Springfield, MO 65802 :: Products + Services

__________________
This post brought to you by Carl's Jr.

Down here in atlanta they'd do it for roughly 150$ and it would be balanced. Surely there is a driveshaft shop somewhere in between here and Franklin that could do it for a reasonable amount

Did you read through this thread? there is some measurements shown.

240D 4-speed manual swap in 300CD


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

$90 balanced.


16 eh? Forgot about that. I can't even be seen around you!

__________________
http://superturbodiesel.com/images/sig.04.10.jpg
1995 E420 Schwarz
1995 E300 Weiss
#1987 300D Sturmmachine
#1991 300D Nearly Perfect
#1994 E320 Cabriolet
#1995 E320 Touring
#1985 300D Sedan
OBK #42