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#1
03-13-2019, 12:18 PM
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W123- 4spd manual into 300d vs Om617a into 240D
So
I currently have a US spec '83 300d. Wonderful mechanically. Starts up on the first revolution or so, doesn't leak oil, doesn't even really smoke unless it's super cold out and even then it's just a puff on start up. fresh nozzles, glow plugs, etc. Shifts pretty nicely. Pretty horrible cosmetically. Core support/ frame damage from previous owner. Leaks a little water in when raining from a wide array of locations. Bad door seals. A/C system would have to be totally re done (lines leading to nowhere, parts missing, etc). I have been driving the car for two years now and it has been bulletproof after I changed the nozzles, one prechamber, and the glow plugs. I found a manual 240d for sale not too far from me. Also an '83. Power windows, power sunroof. Manual climate control (which I think I prefer over the auto in my 300) It is in much, much, much better cosmetic shape than my 300d. How much trouble is it to swap the om617 from my '83 300d into the '83 240d? More trouble than swapping the trans + all associated parts into the 300d? Or not?
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'84 300D Euro 5 spd '83 240D 4spd '83 300D/5 spd manual/Lifted+28" AT Tires '83 300SD '10 E63 Parting out- '79 Euro 280TE Green/Green & '89 300SEL White/Grey 
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#3
03-13-2019, 01:04 PM
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It shouldn't be too difficult to swap the 5 cylinder in. You will need to shorten the drive shaft, swap the trans cross member over, but it is essentially a bolt in swap. Not sure of what needs to be done with the shift linkage.
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Milan Brown 1979 240D, rebuilt OM617.952 turbo diesel, rebuilt 722.315 transmission - engine spun a rod bearing 1979 300SD, ~90k original miles, all stock
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#4
03-13-2019, 02:47 PM
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I think you need the adapter plate off the back of the 616 motor, the auto trans doesn't have the same bolt pattern.
The 617 motor is heavier, you'll probably want to transfer the springs or get new ones spec'd for a 300D instead of a 240D. The rear end ratios are different. Decide which one best suits you and if you swap, swap the speedo/instrument cluster too. When you break the driveshaft, mind the alignment. The FSM documents how it's marked by year, you'll want to put it back the same way. There are 617 specific parts for the manual transmission- heavier flywheel and a shaft mounted damper. My 300TD w/ 4 spd came with these and drives fine, some people who swap a 617 into a 240D/4 spd have complained about persistent & adverse vibration with the combo. The transmission will move back in the tunnel, far that people have to shorten the driveshaft, IDK if you have to make new holes to mount the transmission or just use the other set already in the body. The amount of space around the transmission in the new location is small enough that it sucks quite a bit. You'll have to shorten the manual transmission shift linkages, I've posted in detail about getting the shift bushings and linkages right if you search for my posts on it.
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CC: NSA All things are burning, know this and be released. 82 Benz 240 D, Kuan Yin 12 Ford Escape 4wd You're four times It's hard to more likely to concentrate on have an accident two things when you're on at the same time. a cell phone. www.kiva.org It's not like there's anything wrong with feeling good, is there?
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#5
03-14-2019, 09:44 AM
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Excellent info, thanks everyone. I will investigate further when/if I get the car.
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'84 300D Euro 5 spd '83 240D 4spd '83 300D/5 spd manual/Lifted+28" AT Tires '83 300SD '10 E63 Parting out- '79 Euro 280TE Green/Green & '89 300SEL White/Grey
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