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Old 06-15-2016, 04:10 PM
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Join Date: Mar 2016
Location: Tulsa, OK
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240 Trans Swap


I've seen a zillion posts about transmission swaps with all kinds of great technical information. However, I can't seem to find some more simple answers.

I have a 77 240D on which I'm starting to think about swapping the poor but exuberant automatic transmission for a manual. My car came with a 722.117. I'm told by MB Classic Center that, if it were shipped with a manual, it would have been 716.005.

How tight do I need to stick to that .005 transmission? Since it's all vacuum, I don't want to stray too far.
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Old 06-15-2016, 04:35 PM
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Join Date: Apr 2005
Location: Cicero, Hamilton County, Indiana about 30 miles north of downtown Indianapolis
Posts: 2,609
Why do you worry so about the vacuum? It affects nothing on the manual, so if you have a line going to the automatic, just plug it off. Either of the two 4 speeds will work with no problems and no vacuum. Vacuum on that old a model would have been applied only to cruise control, P Brakes, door locks and engine stop. If those items work now, they will work as well with the new transmission. If you are looking for parts for the swap I have them all.
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,
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Old 06-15-2016, 05:02 PM
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Location: Wilmington, NC by the Atlantic ocean
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If my info is correct, yours would have had the cast iron case Mercedes-made manual - the later cars (not sure of the year of the change) had a Getrag-sourced aluminum case 4 speed. I have the Getrag and it's been perfect - I pilfered the trans and linkage from an '83 240D.

It should be a pretty straightforward swap with the hard parts being:

1) Find out if your current flywheel is neutral balanced or not. Before removing the current flywheel be sure to mark it so you know its orientation. Take both flywheels to a balancing shop (most towns of any size will have a company that does industrial balancing) and have them check balance and mark the manual flywheel to match the automatic one. Align your marks and off you go.

My engine/flywheel combination was, evidently, neutral balanced so I got away with it but so far I have not been able to find any info on which combos are neutral balanced and which are not. If I had known a bit more when I did mine I would have done the procedure as detailed above.

2) You'll need to transfer all the clutch bits. Remember that the clutch linkage is hydraulic and on the M-B used the brake reservoir as a fluid source (I got around that in my hybrid Chevy/Mercedes system). These are notoriously difficult to bleed but most of us have had the best luck pressure bleeding it from the slave back up to the master - I use a veterinary syringe filled with brake fluid that forces fluid up to the master as I push the plunger. With an all-Mercedes system the guys say the factory instructions work pretty well.

3) The actual installation is pretty straighforward - just nuts and bolts. Make sure your rubber driveshaft biscuits and such are in good shape - again, I don't use them so I don't have any insite on those details.

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Old 06-15-2016, 05:06 PM
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Join Date: Mar 2016
Location: Tulsa, OK
Posts: 80
Yes, it's a 77 W123
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