Did you remember to plug the vac line going to the auto tranny? I forgot to do that on my 190D 5 speed swap and it wouldn't shut off with key. Plugged it and all good. Nice Job!

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What Would Rudolph Do?
1975 300D, 1975 240D, 1985 300SD, 1997 300D, 2005 E320 , 2006 Toyota Prius

Thanks Pete! I did plug the vac line going to the transmission. It stopped "dieseling" on its own. Not sure why it did that, seems to be fine now.

The hissing is definitely coming from the brake rod/booster area. I really beat on it trying to get the clutch bled with the caliper method...

It only hisses when I put moderate to heavy pressure on the brake pedal, but the pedal stays firm.

I wonder if I blew out the booster seals, hope not...

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'82 300TD
'84 300D OM617
Auto to 4spd Manual Swap 716.210
'85 300SD 2.88 Diff (Direct Swap)
W140 HD Rear Springs w/ bilstein shocks (SLS Delete)
'83 300SD Big Brake Booster Swap
Late model 240D Manual HVAC Swap
W124 Outside Temp Gauge
Aftermarket Keyless Entry

'84 300D RIP

This thread may be relevant to your shifting issue:

4 Speed Getrag Question

Also, have you seen the tranny run before? Could it just be a blown synchro or something?

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"Senior Luna, your sense of humor is still loco... but we love it, anyway." -rickymay ____ "Your sense of humor is still loco... " -MBeige ____ "Señor Luna, your sense of humor is quite järjetön" -Delibes

1982 300SD -- 211k, Texas car, tranny issues ____ 1979 240D 4-speed 234k -- turbo and tuned IP, third world taxi hot rod

2 Samuel 12:13: "David said to Nathan, “I have sinned against the Lord.” And Nathan said to David, “The Lord also has put away your sin; you shall not die."

On the soft clutch I think its normal. I have driven two 4 speed swapped W123 cars and the clutch is softer than you would expect. I thought I messed something up since the clutch in my W124 300E is pretty firm.

Was just wondering about doing this into a 300CD. Will look more (this thread was right on top) but curious how common that is and the best way to find parts and the right person to do it.

Hissing Solved! It was the booster. I went to the North Houston LKQ Pick and Pull today and grabbed a Big Booster from an 83 300SD. They have three 300sd's and one 300d. Most of their parts still there. There was also an 80s 300E in there.

Direct bolt in swap, I reused my Master on it. Also, I managed to finagle it in without disconnecting any brake lines. Only had to pull the clutch hose and cap the reservoir. I was a little worried about the clutch hose reaching the master but ended up having plenty of slack.

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'82 300TD
'84 300D OM617
Auto to 4spd Manual Swap 716.210
'85 300SD 2.88 Diff (Direct Swap)
W140 HD Rear Springs w/ bilstein shocks (SLS Delete)
'83 300SD Big Brake Booster Swap
Late model 240D Manual HVAC Swap
W124 Outside Temp Gauge
Aftermarket Keyless Entry

'84 300D RIP

Shouldn`t be any different than swapping in a 4-spd into a 300D.
Just source the parts from a 240D with manual transmission.

You will need to use the transmission cross mount from a 240D automatic trans. The cross mount for a 240D manual will not work, as you are moving the mount back a set of holes. I believe a 280E uses the same mount.

Charlie

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there were three HP ratings on the OM616...

1) Not much power
2) Even less power
3) Not nearly enough power!! 240D w/auto

Anyone that thinks a 240D is slow drives too fast.

80 240D Naturally Exasperated, 4-Spd 388k DD 150mph spedo 3:58 Diff

We are advised to NOT judge ALL Muslims by the actions of a few lunatics, but we are encouraged to judge ALL gun owners by the actions of a few lunatics. Funny how that works

Thanks for the link! Yes, I think thats my problem with the grinding in reverse... The Pilot bearing was the most difficult part of the swap for me by far... I ruined the first one trying to get it in the crank (made it Italy on it). I got a new one from NAPA that was made in the Japan. It fit better but was still a VERY tight fit. Its definitely possible that I didnt get it in perfectly straight. For now, I will just start it already in reverse if I need to back up, and avoid situations where I need to back up while running.

Never saw the trans run. I pulled it from a 240d that had a rod sticking through the block, but only 112k miles on it.

The 2nd gear downshift grind was just me being rusty with a stick shift. Shes shifting smooth in all forward gears. I put Mobil 1 ATF in the case.

She tachs the same rpms on the highway as the auto did which makes sense as they both have 1:1 4th gear ratios. Hmm now to look for a 2.88 rear diff.

__________________
'82 300TD
'84 300D OM617
Auto to 4spd Manual Swap 716.210
'85 300SD 2.88 Diff (Direct Swap)
W140 HD Rear Springs w/ bilstein shocks (SLS Delete)
'83 300SD Big Brake Booster Swap
Late model 240D Manual HVAC Swap
W124 Outside Temp Gauge
Aftermarket Keyless Entry

'84 300D RIP

Update!

Finally got around to pulling the trans again. She was making a lot more scraping and grinding noises.

Found that the wedged in pilot bearing had flung its grease as was probably close to seizing.

After cutting it out with my dremel, I used my cylindrical grinder attachment and went around the crank hole about twenty or so times using steady pressure.

New pilot bearing tapped right in like it should have to begin with.

Trans input shaft slipped right in and trans to engine was flush with only a little wiggling.

Result:

No more grinding reverse! No more grinding 2nd or any other gear!

__________________
'82 300TD
'84 300D OM617
Auto to 4spd Manual Swap 716.210
'85 300SD 2.88 Diff (Direct Swap)
W140 HD Rear Springs w/ bilstein shocks (SLS Delete)
'83 300SD Big Brake Booster Swap
Late model 240D Manual HVAC Swap
W124 Outside Temp Gauge
Aftermarket Keyless Entry

'84 300D RIP

Good to see this issue resolved.

.

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ASE Master Mechanic
https://whunter.carrd.co/

Prototype R&D/testing:
Thermal & Aerodynamic System Engineering (TASE) Senior vehicle instrumentation technician.
Noise Vibration and Harshness (NVH).
Dynamometer.
Heat exchanger durability.
HV-A/C Climate Control.
Vehicle build.
Fleet Durability
Technical Quality Auditor.
Automotive Technical Writer

1985 300SD
1983 300D
2003 Volvo V70

https://www.boldegoist.com/

617 Flywheels are definitely not all balanced neutral. You were lucky.

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Chris
84 280sl
82 300d euro

I had a flooded engine and tranny when I bought back my 84 280e euro. There was some water in the tranny. We rinsed it out and I got years of use out of it before the second gear synchro failed.

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[SIGPIC] Diesel loving autocrossing grandpa Architect. 08 Dodge 3/4 ton with Cummins & six speed; I have had about 35 benzes. I have a 39 Studebaker Coupe Express pickup in which I have had installed a 617 turbo and a five speed manual.[SIGPIC]

..I also have a 427 Cobra replica with an aluminum chassis.