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  #1  
Old 04-11-2003, 12:41 PM
philip kim
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Question Swapping auto trans with stick

I am in a process of purchasing 300 tubo diesel with automatic transmission and I would like to change it to stick.

How do I do this?
Is it possible?
Recommended transmission from which model?
I heard there is a five (5) speed manual gearbox, is this true?

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  #2  
Old 04-11-2003, 02:37 PM
LarryBible
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The five speed is RARE in the US. There was a group of people here that were talking about a connection for getting them from Poland.

A four speed would be more practical.

Be warned that you will need many more parts than just the transmission. You will need a shifter, probably a driveshaft(or make one) clutch linkage, clutch components, flywheel etc.

Research and think through your gear ratios and rear axle ratio carefully.

Good luck,
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  #3  
Old 04-11-2003, 02:57 PM
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THat was me with the hopeful Poland connection... but I have not heard anything from him in weeks.... but he is draft age and may be in the gulf States with more to do than worry about manual trans in MB's ....
We also talked about finding someone like KEP to make an adapter for an American 5 speed to put behind them....
Do a search for " ridge" and for 'adapter' ... should have enough reading to keep you busy a day or so....
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  #4  
Old 04-11-2003, 03:03 PM
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Check this out....

http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&category=6330&item=2409884769&rd=1


Does anyone know if this is one of " us" on the forum ?
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  #5  
Old 04-11-2003, 04:35 PM
LarryBible
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This five speed has the same interior as my "Ol' Silver." My seat is worn as is that one, but not nearly as bad. The Euro cars have larger seat bolsters that get wear every time you get in or out.

Have a great day,
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  #6  
Old 04-11-2003, 10:17 PM
Breckman99's Avatar
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Well if anybody does find anything out about getting a adaptor plate made or a good surplus of 5 - speeds let me know Id be intrested for sure.
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  #7  
Old 04-12-2003, 07:53 PM
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Not sure if the crankshaft is drilled to accept a pilot bearing
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  #8  
Old 04-12-2003, 09:36 PM
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I think it is... this has been talked about.. BUT if it isn't.... That is what drill bits are for.... LOL
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  #9  
Old 04-12-2003, 10:40 PM
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Leathermang

I have heard that sometimes you find a crank that has not been bored for the pilot baring and was told that a crank is too hard to be bored (616 engine).????? Maybe another "old wives" tail ? I have a 4 spd tranny I was hoping to mate with a 616 from an automatic doner car and was thinking what a drag it would be to buy the car, pull the engine only to discover there was no way to install the pilot baring. If it is possible to drill, the crank would have to be removed from the engine ? Finding a good engine from an automatic 240D to put into your 240 manual wouldn't be an uncommon event IMO
Have a good evening
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  #10  
Old 04-12-2003, 10:54 PM
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I have all sorts of catalogs from Tool Makers who would be aghast at the suggestion that some metal was too hard to make a hole in....
It may have been too hard for the guy that told you that , however.... So trust that he was telling His truth.... but if you find you need a pilot hole email me...
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  #11  
Old 04-13-2003, 03:29 AM
dzldog
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Exclamation DO IT!

5-speeds are hard to find (unless you order one from over-seas - Yes that 300D on eBay would have been a candidate). I used a 4-speed manual from a 240D and find my new gearbox to be very comfortable at all speeds, though I did upgrade to 16" wheels to compensate for the lower gearing.
You may find buying an entire 240D the best route (that's what I did), since you will need many of the parts. Find one with a good clutch, clutch master cylinder, and transmission.
Here's what you will need to do:
Obviously, remove auto. transmission, entire drive shaft and center baring, shifter, and brake pedal assembly from the 300d. This will entail removing the exhaust, and dropping the engine a bit to expose the nearly impossible to reach top tranny/engine bolts.
Also, remove the stock 300D flywheel - hopefully in your case none of star headed bolts strip. Three did for me, thus I spent quite a bit of time drilling the heads off!
You will need to take the complete 240D drive shaft and bearing assembly to a good dirve shaft shop to have shortened and balanced. Since the 5 cylinder engine is longer and the manual transmission is shorter than the AT, neither stock front drive shaft will fit... Note that it will be your responsibility to determine the lenght the 240D front shaft will need to be cut back to - be certain to check your math, else you may end up with an expensive lawn ornament! The bearing and rear half are interchangeable, so you can pick the best parts there. This cost me about $300.
The manual tranmission shift rods will need to be shortened the same amount as the 240D front drive shaft... get out your hacksaw.
Swap the brake pedal assembly w/ that from the 240d manual - again, acquire one with a good clutch master cylinder.
The 300D crank shaft is drilled for a pilot bearing. I'm not certain if it is a readily available size, however. I had a shop grind and slightly larger one down to fit...
Install a 240D or manual tranmission 300D flywheel. Make certain the clutch surface is smooth.
I would suggest replacing the slave cylinder on the manual transmission before installing it. It may save time and hassle later. Also, replace the flexdiscs on the dif. and transmission.
The rest is straight forward. Oh, you will need to modify the wiring for the reverse lights and starter cut-off. You will be able to remove the accelerator linkage on the head with some slight modifications, which results in less clutter and great improvement in pedal response.
I would strongly suggest going through with such a project. Acceleration is improved quite a bit. The result is a much more fun diesel (who needs a VW TDi?).
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  #12  
Old 04-13-2003, 01:43 PM
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dzldog, going with a separate clutch actuator oil reservior may be easier than the brake pedal assembly switch. Cheap at the junkyard, and makes brake bleeding an easy drill, but don't tell anyody you put an American or Japanese part in your Benz!
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  #13  
Old 04-13-2003, 07:18 PM
dzldog
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Dabenz:
I'm not sure I understand what you mean.
It's only four bolts that attach the pedal assembly to the brake master cylinder. I found the swap to be easy enough.
As far as the reservoir goes, there is already a nipple on that of the 300D which simply needs to be cut open.

Last edited by dzldog; 04-13-2003 at 08:07 PM.
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  #14  
Old 04-14-2003, 12:18 PM
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I'm a fan of separate systems. My pickup and other car have separate circuits for the clutch. It's another reservoir, but it's also a lot easier to bleed one system at a time (at least for me). It's on the list for daBenz.
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  #15  
Old 04-14-2003, 12:53 PM
dzldog
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I see your point in using two reservoirs now. Perhaps I will do that myself.

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