I am having Chronic "locking" and "catching" and "missed gear" shifter problems with my 1983 240D and its really driving me crazy. I dont think the problem is the Transmission since they are supposed to be really tough, and I have replaced all the shifter bushings and tightened the Linkages and aligned them and realigned them carefully.
The other day I lost 3 rd gear and 4 th Gear in the mountains for awhile ahead of a Big Truck until I really whacked the shifter and unlocked it
I am wondering whether the problem is the shifter assembly itself? Do these ever go bad?
I have corrected everything else--the shifter calibration, the bushings and linkages.

240D Shifter Problems--almost got me flattened on Highway

Are you absolutely sure the clutch is releasing? If the driveline is under load (either accelerating or decelerating) and the clutch doesn't release, the transmission will be very hard to get out of gear.

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Rick Miley
2014 Tesla Model S
2018 Tesla Model 3
2017 Nissan LEAF
Former MB: 99 E300, 86 190E 2.3, 87 300E, 80 240D, 82 204D Euro
Chain Elongation References

There are mountains In South Jersey? Maybe that's the problem.

Seriously, have you tried lubricating the shifter assembly? It may be binding occasionally because of a lack of lubrication.

It may also be caused by debris or a broken part in/on the shifter which is preventing movement. On my project 240D transmission, the reverse light actuating tab was severely bent and wouldn't always allow the shifter to fully move to the left.

A piece of debris could have the same effect.

Try removing the shifter boot and inspecting the top of the shifter assembly for these two issues.


Good luck,
R

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Never a dull moment at Berry Hill Farm.

I have had the same problem with reverse and first on my 1983 240D. It doesnt wanna go into gear, until i really smack it. The reverse tab is fine, and I don't know about the lubrication.

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Nick
*****
2002 Sprinter 2500 140" High Roof :

You've also got some rubber bushings in the linkage that wears out and sometimes falls out. It caused me to lose everything but fourth gear a few times. Replaced all those bushings and all is well again. Cheap and easy fix. You should also tighten up the allen headed bolt inside the conection where the linkage connects to the transmission.

Len
'83 240D 335,000 miles original owner

I suggest you take the shift mechaism out take it apart and clean/lubricate. When I got my car I looked up at the shift mechanism from below and could see that some of the shift "keys" that move the levers were loose. I took mine apart and found that the PO or someone had some of the shims in backwards. After I corrected this , rebushed part of it and lubed it , it worked much better. The Haynes manual has a very good illustration. This is a very simple, durable and precise mechanism- don't be afraid of it. With proper infrequent attention it will last a long time and enhance the unique 240D experience.

Rick

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80 300SD (129k mi) 82 240D stick (193k mi)77 240D auto - stick to be (153k mi) 85 380SL (145k mi) 89 BMW 535i 82 Diesel Rabbit Pickup (374k mi) 91 Jetta IDI Diesel (155k mi) 81 VW Rabbit Convertible Diesel 70 Triumph Spitfire Mk III (63kmi)66 Triumph TR4a IRS (90k mi)67 Ford F-100 (??)