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  #1  
Old 07-23-2013, 02:46 PM
zeke's Avatar
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Location: The Alamo City, TEXAS
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4-sp Manual transmission shifter picture

I need to replace my shifter bushings, but there aren't any nice pictorials of the job that I can find. I have looked in the book I have with all the different diagrams (same pictures EPC has), but I can't find the shifter in any of the plates - missing from the console plate and missing from the transmission plate, AFAICT.

Can someone post a diagram of the 4-sp shifter so I can see what to expect and how to access the bushings?

The writeups I have seen for the M/T have not been very detailed.

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Current Mercedes
1979 maple yellow 240D 4-speed


Gone and fondly remembered:
1980 orient red 240D 4-speed

Gone and NOT fondly remembered:
1982 Chna Blue 300TD

Other car in the stable:
2013 VW Jetta Sportwagen TDI / 6-speed MT
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  #2  
Old 07-23-2013, 02:50 PM
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I have the shifter and rods but I didn't save the interior parts as I won't use them in my application. Will pics of what I have be helpful?

Dan
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  #3  
Old 07-23-2013, 02:57 PM
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I would be a start, thanks!
__________________

Current Mercedes
1979 maple yellow 240D 4-speed


Gone and fondly remembered:
1980 orient red 240D 4-speed

Gone and NOT fondly remembered:
1982 Chna Blue 300TD

Other car in the stable:
2013 VW Jetta Sportwagen TDI / 6-speed MT
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  #4  
Old 07-23-2013, 05:22 PM
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Maybe this would be helpful.

http://mb.ilcats.ru/part/class/1/ccode/F/cat/68K/type/123/subtype/123/group/26
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Junqueyardjim
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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  #5  
Old 07-23-2013, 05:33 PM
zeke's Avatar
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YES! Thanks, that is what I was looking for!
__________________

Current Mercedes
1979 maple yellow 240D 4-speed


Gone and fondly remembered:
1980 orient red 240D 4-speed

Gone and NOT fondly remembered:
1982 Chna Blue 300TD

Other car in the stable:
2013 VW Jetta Sportwagen TDI / 6-speed MT
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  #6  
Old 07-23-2013, 07:00 PM
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Location: Out in the Boonies of Hot, Dry, Dusty, Windy Nevada
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Will this help?

http://www.peachparts.com/shopforum/diesel-discussion/335351-manual-transmission-shift-assembly-rebuild-video.html


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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  #7  
Old 07-23-2013, 07:14 PM
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Sort of.....hope whunter gets around to making that video, though I need to do this last week, so I doubt it will be posted before I start pulling the shifter out myself.

Would a 6mm allen key work as a retaining rod?
__________________

Current Mercedes
1979 maple yellow 240D 4-speed


Gone and fondly remembered:
1980 orient red 240D 4-speed

Gone and NOT fondly remembered:
1982 Chna Blue 300TD

Other car in the stable:
2013 VW Jetta Sportwagen TDI / 6-speed MT
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  #8  
Old 07-23-2013, 09:20 PM
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I got tied up today but I'll shoot some pics tomorrow - I promise!

Dan
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  #9  
Old 07-24-2013, 12:05 PM
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OK Zeke - here's the promised pics:

1) Overview with the trans.

2) Shifter with one end of the rods. Darn if I can remember which end of the rods go which way but the drawing in the manual will show that.

3) Transmission shift arms. My rubber bushings look fine but I think I have new ones around here someplace.

4) The plain end of the rods. Notice that there's a groove around the rods to hold the retainer. Assuming you're ordering parts I'd be sure to get new retainers (not sure what they call them in the catalog).

5) Close up of the "big" end of the rods. The new bushings clip right in there.

The actual shifter body on mine seems fine so I have no plans to mess with it at this time. I'll clean it and lubricate with lock-ease or some such but there doesn't seem to be any reason to disassemble. The bushings, however, were in pretty bad shape.


Hope this helps

Dan
Attached Thumbnails
4-sp Manual transmission shifter picture-img_0644.jpg   4-sp Manual transmission shifter picture-img_0645.jpg   4-sp Manual transmission shifter picture-img_0646.jpg   4-sp Manual transmission shifter picture-img_0647.jpg   4-sp Manual transmission shifter picture-img_0648.jpg  

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  #10  
Old 07-24-2013, 05:11 PM
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Location: Out in the Boonies of Hot, Dry, Dusty, Windy Nevada
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The 6mm Allen will probably work. you are referring to keeping the shifter levers aligned in the neutral position? a Nail or Drill Bit of the correct size will work also.

In Dan`s pictures, the Aluminum screw on ends, connect to the Shifter, the "L" end connects to the Transmission. Good Pictures Dan.

I took apart one Shifter to clean it and grease it up. the most difficult part was getting the 2 springy washers back in.

I found this thread that might be of some help, shows parts and an exploded picture.


http://www.peachparts.com/shopforum/mercedes-used-parts-sale-wanted/301562-fs-w123-manual-transmission-shifter-assembly-renew-kit.html

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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  #11  
Old 07-25-2013, 11:53 AM
zeke's Avatar
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Join Date: Sep 2007
Location: The Alamo City, TEXAS
Posts: 1,189
Thanks all,

I am going to the dealership today to order parts - hope to do this in the next week or 2.
__________________

Current Mercedes
1979 maple yellow 240D 4-speed


Gone and fondly remembered:
1980 orient red 240D 4-speed

Gone and NOT fondly remembered:
1982 Chna Blue 300TD

Other car in the stable:
2013 VW Jetta Sportwagen TDI / 6-speed MT
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  #12  
Old 07-25-2013, 02:34 PM
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Location: Mount Holly, NC
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I need to do this as well to my two euro manual cars....
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John HAUL AWAY, OR CRUSHED CARS!!! HELP ME keep the cars out of the crusher! A/C Thread
"as I ride with my a/c on... I have fond memories of sweaty oily saturdays and spewing R12 into the air. THANKS for all you do!

My drivers:
1987 190D 2.5Turbo
1987 190D 2.5Turbo
1987 190D 2.5-5SPEED!!!

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1987 300TD
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  #13  
Old 07-26-2013, 01:56 PM
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Just be aware there there are differences between the early 4 speed set ups and the later 82-83 parts.
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  #14  
Old 08-02-2013, 11:25 AM
zeke's Avatar
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Join Date: Sep 2007
Location: The Alamo City, TEXAS
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leak at shift arm

So I finally got under my car today, and there is an obvious leak where the forward-most arm connects to the transmission

Is this a problem? Is this a diy?
Attached Thumbnails
4-sp Manual transmission shifter picture-img_20130802_091537_270.jpg  
__________________

Current Mercedes
1979 maple yellow 240D 4-speed


Gone and fondly remembered:
1980 orient red 240D 4-speed

Gone and NOT fondly remembered:
1982 Chna Blue 300TD

Other car in the stable:
2013 VW Jetta Sportwagen TDI / 6-speed MT
Reply With Quote
  #15  
Old 08-02-2013, 11:59 AM
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Location: Wilmington, NC by the Atlantic ocean
Posts: 2,510
First question is "how much"? We'll need some of the more experienced folks to chime in here but I don't know if you can replace this from the outside of if you'll need to pull and disassemble the gearbox. If the box needs to come apart you may want to do the R&R (mechanic speak for "remove and replace) yourself and take it to a GOOD transmission shop for the fix.

But if the transmission is not down on fluid very much and it's not gushing fluid you may just want to check it frequently and let it go for now.

Dan

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