I was able to locate a clutch alignment tool for mine when I replaced the ring gear. Call your various transmission parts specialists. I was able to get one for $3. Everything seems to be going smoothly, in fact my clutch was making some kind of weird noise before I removed it and put it back in, and now that's gone, so...

Although I admit I didn't know anything about these witness marks you're talking about, so hopefully that won't come back to haunt me.

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'78 240D

Randy

"clutch alignment tool "

The shaft off the front of a "80s' Volvo tranny is the same as an MB,.. spline wise. My buddy with the import repair shop, dug around in his scrap pile and found me one, worked great, thought I would pop in and see how you were doing

Steve

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1985 Euro 240D 5 spd 140K
1979 240D 5 spd, 40K on engine rebuild
1994 Dodge/Cummins, 5 spd, 121K
1964 Allice Chalmers D15 tractor
2014 Kubota L3800 tractor
1964 VW bug

"Lifes too short to drive a boring car"

Hmmm, to the vehicle, every MB with an auto that I've checked (many in junkyards and the 4-5 I've worked on here) have NOT had ANY witness marks on the crank OR the auto tranny flywheel???

You SURE about a witness mark on the auto tranny crank???

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1984 300D Turbo - 4-speed manual conversion, mid-level resto

1983 300D - parts car

1979 300TD Auto - Parts car.

1985 300D Auto - Wrecked/Parts.


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"If you don't know where you are going, any road will get you there". Lewis Carrol

Pretty darned sure...they were in the two places that the FSM says they're supposed to be. There are a lot of scratches in the relief hole but one mark was obviously made by striking with a tool. The mark on the flange wasn't as distinct (it looked to me like it was made with a motorized engraving tool) but was in alignment with the mark back up in the relief.

I do not think you could spot these marks under the layer of crud that was there. I sprayed Brakekleen and wiped like a fiend then looked at it with my 3X readers (getting old and blind is a PITA).

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Never a dull moment at Berry Hill Farm.

Funny. Who would ever think you could buy a specialized Mercedes-Benz™ clutch installation tool for $1.89 from O'rileys auto parts?

Motormite 14522
Dorman 691-501

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Never a dull moment at Berry Hill Farm.

Well, I guess you get what you pay for.

And at $1.98, the Motormite clutch tool does work but, only if you alter it by forcing it through the old clutch disk several times to broach the plastic splines enough to permit the tool to slide (relatively) freely.

Still, I was able to install the clutch and get the transmission up and bolted in place last night. All the linkages are in place too

I also had to remanufacture the shifter linkage bushings that I'd made earlier. They were a little too narrow and allowed the rod ends to slip off the bushing. FWIW, I found hard nylon bushing marterial with the right ID at Loews Home Improvement. If these homemade bushings don't seem to work out, I'll go ahead and spring for replacement rod ends.

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Never a dull moment at Berry Hill Farm.

I can probably turn some on the lathe from teflon or whatever other stock, maybe I'll look at doing that and make a few dozen of them.

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1984 300D Turbo - 4-speed manual conversion, mid-level resto

1983 300D - parts car

1979 300TD Auto - Parts car.

1985 300D Auto - Wrecked/Parts.


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"If you don't know where you are going, any road will get you there". Lewis Carrol

Driveshaft in place, flex disks secure. Speedo cable installed.

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Never a dull moment at Berry Hill Farm.

Shifter rods installed and adjusted, shifting action checked.

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Never a dull moment at Berry Hill Farm.

Rear mount in place...the rubber mount really needs to be installed onto the transmission before the flex disks go on. There's NO clearance to get a box-end or socket on there!

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Never a dull moment at Berry Hill Farm.

Here's the clutch hydraulic hose and where it connects onto the brake reservoir. This took about 18" of 9mm ID braided hose.

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Never a dull moment at Berry Hill Farm.

Here's where it all came unraveled like a cheap sweater. When trying to bleed the clutch system I somehow managed to pull the supply line out of the master cylinder while the system was under pressure from my power bleeder, thereby irrigating the floorboard with brake fluid.

Talk about POed.

I'll return to the scene of the crime tonight with a fresh outlook and finish things up.

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Never a dull moment at Berry Hill Farm.

That's a bummer about the brake fluid, but it really looks like you're close to being done! What more do you have to do at this point?

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'78 240D

Bleeding the clutch and doing some provisional wiring to get around the old transmission's neutral/park safety should have me back on the road. Eventually, I'm going to use the neutral/park safety to provide a clutch safety switch; I'll incorporate a starter kill as a theft prevention device in there as well.

And, I don't have a shifter boot so there are some cosmetic issues to deal with.

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Never a dull moment at Berry Hill Farm.

Shifter boots are on Ebay all the time, but don't buy one there. Fastlane is actually cheaper. And you might want to look up some pictures of how they are fitted, because it doesn't seem like it fits right when you put it on.

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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