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  #1  
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

Everyone,

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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  #2  
Old 06-15-2016, 04:35 PM
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Location: Cicero, Hamilton County, Indiana about 30 miles north of downtown Indianapolis
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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.
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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.

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