SilverFox123 - BTW - did you read post #215 on page 15?

Also, which "diesel" transmission do you have, because the .411 has a 0.75 fifth gear, not 0.82.... they are all different, you need to check the exact code of the tranny and look up the gear ratios. With the .411 tranny, differential gears closer to 3.46 would be nicer (which is exactly what the factory combo was). The 3.27's are kinda tall for the OM602 turbo powerband.

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Hey guys, sorry to disappear after the advice and thank you!
I've beat my brain enough and am onto the "doing" phase.

My decision is a .411 trans from an '87 190D N/A manual car. The .410 (2.2 diesel) trans was almost perfect with the 3.27 with the exception of the OD gear. It was just too high revving on the highway for me to bite. So I'm going to try the .411 with 3.27 LSD for my winter setup and if it is too tall, swap it with a 3.42 open from an old 2.2D. Whatcha think?

Still have a pile of questions ...

For kicks: Are there any w201 (or w124's compatible) differentials that were 3.46? I can't get a straight answer ... looked like the EVO I's had a 3.46 LSD or ASD. The stock euro manual 190D-t's had a 3.46 and I thought it would be worth an investigation even though the 3.42's are everywhere and damn close to the euro stock ratio.

For real: I am in the process of getting all the new bits for my swap and wasn't sure exactly what was worth throwing on while I'm in there. If i can get any help on the following, I'd be muchly obliged!

-Which clutch would people recommend?
The stock is an 8.5 inch but should it be beefed up? Would a straight up stock Sach kit be fine?
Would a better bet be a 9 inch (still stock Sach) from a later 190E? Or would a stage 2 or 3, 8.5 inch be best? Say spec or clutchnet?

-New pilot and throw out bearings?

-New trans and diff mounts? I heard the manual engine mounts are different ... not sure about the others.

-Intermediate bearing? Flex Discs? Buy new?

-Seals ... any to grab while I'm at it? Rear engine seal? Diff/ trans shaft seals?

-Master and slave cylinders. New or rebuild?

-Hydraulic clutch hoses ... any source on these? Could they be made or bought at a local hyd. shop?

-Also, I heard mention of some spacer/cap involved in the clutch or driveline. I can't find out any more about them, and no others mention them but don't want to shoot myself in the foot.

Any help would readily be ingested and many thank in advance!

SF

Ok the "project" car is going into winter DD status. I finally got a good used blower motor installed. I will report any success or failures. And since I got a working odometer and almost correct speedo head, I can figure out mpg's. Not to mention my nice-n-dry IP.

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08 R320 CDI current

Past
95 E420
87 300D Turbo 5spd
90 300TE
83 300SD
85 300TD
92 400E
85 190D

This is by no means scientific:

My first fuel calculation with the new diff ratio- 24 mpg in the city, with spirited driving . 5 gallons to fuel light was 120 miles. Put another 5 in today and will see if I make 120 again.

I would like to see 28 in the city, but I might need to go back to using the ALDA. 35 mpg on the highway and I would be a happy camper. Remember I turn 2100 rpm at 65 mph.

Other notes:
Drove in snowy/slick conditions today. Even with new snow tires I'm getting wheel spin if I dont watch it. A sandbag or two may be in order(helped in my 400E). Starting in 2nd may be an option, but for now I would rather save the tired clutch.

Shifting is getting better(with practice) but I can tell it's not all coming together smoothly in the tranny. Could be the shifter rebuild I botched and/or the tranny fluid. I'm using redline but it has been suggested that going back to atf or gear oil may help.

Pulls like a train in the 2500-4000 rpm range, anything more seems like a waste. You gotta shift at higher rpm's(ie 2000+) or you will get lugging. And if you dilly dally(hello that's me) in the shifts you will loose too many rpm's and kinda ruin the show.

I'm still only using 1-2"s of "gas" pedal deflection, anything more and the old clutch slips. Will spin the snows tires/smoke/leave tread/kick out at will from a stop... again, trying to save the clutch.

She definitely prefers to be "driven"... try to granny it and she get's all choppy.

Car still seems really jerky/jumpy... I was blaming the shifting but I now suspect the early 124 seats and the front end. It's real tight in the front but has always sat really high.. something like 6"+ from factory tire size to front fender lip. Could have some really odd springs in it for some reason.

If switching fluids will allow be to downshift to 2nd better(w/o a crunch) then the low speed transitions would be a lot better. Now I'm trying to use 3rd from a turn where I would prefer 2nd. But come to think of it..... I had a convo with someone about my botched shifter rebuild and the fact that it might not be disengaging a gear completely before I try to put in in another..... hmmm I will have to swap shifters for the old one and see.


So far I LOVE driving it... I just wonder if the same setup in a wagon would give the same LOVE?

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08 R320 CDI current

Past
95 E420
87 300D Turbo 5spd
90 300TE
83 300SD
85 300TD
92 400E
85 190D

Great thread. Used quite a bit of information from it.

I just did the swap in my '95 E300D and it's a completely different car now! I used a 717.411 from an '86 190E 2.3. I kept the stock 2.87 diff and the car performs fine, but I wouldn't want anything taller. It turns 2000 rpm at 65 mph, so it is just into the power band at highway speed. My first tank was all highway, half on the automatic and half with the 5 speed, it got 38.57 mpg, incredible!

Like others, I noticed that the car seems to be really jerky now, but it can be managed by driving carefully. Unlike others my clutch (brand new) engages right at half pedal travel, not right at the top. I had my driveshaft made to exactly 33 inches and it came out perfect.

Just thought I would say thanks and share my findings with an E300D.

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dieseleverything

'95 E300D 279k 717.411 5-speed swap 40 MPG
'78 240D Turbo 144k
'83 240D 201k

hmmm this thread has got me thinking.... what would be a good trans combo for a 87 300sdl???

I hate auto trans but I love driving this car so I compromise.

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87 300SDL (work in progress) will be DD
92 Toyota Land Cruiser 4x4 monster (heavily modified)
build thread on mud http://forum.ih8mud.com/80-series-tech/288587-rotf-lt1fire.html

84 K1500 GMC Suburban 6.2 diesel motor...... dying to offer its engine to the Land Cruiser

Start with this so it stops tempting me. Wait for pedals from a Euro MT 126 to show up in the parts forum or in a wrecking yard.

Sixto
87 300D^2

I wonder if people would hate the auto trans so much if they were shifting as the factory intended. You'd be surprised how "badly" most MB auto trannies shift with 200k on them, unknown service history, IP's/VCV's out of adjustment, etc, etc. A fresh 722.3 shifts beautifully.

I've driven a W124 (1993 300D) 5-spd conversion and I wasn't overly impressed, but they sure get fantastic MPG. Good for hypermilers or long freeway commutes at least. I couldn't live with one in city traffic though. Ugh.

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I tend to agree. I think my 722.4 was shifting fine, maybe a little "off" at times especially when cold, but I had no trouble with it. I have read that the 722.4 is not as strong as previous versions and many fail around the 250k mark. Mine was getting close to that and rather than wait for it to fail and spend the money on a rebuild, I saw a 5 speed at the yard and jumped on it. Now I have a good 722.435 to put in another E300D if I ever find a good one with a bad trans.

I was also unimpressed with the lack of smoothness. I'm not sure why it is the way it is, but the car makes up for it in fuel mileage. My second tank yesterday gave me 39.28 mpg.

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dieseleverything

'95 E300D 279k 717.411 5-speed swap 40 MPG
'78 240D Turbo 144k
'83 240D 201k

Well maybe hate was a strong word.... I just love a good manual transmission. Always had... the only vehicle I will keep an auto in if I had a choice is my land cruiser and that is just because it makes off roading that much easier.

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87 300SDL (work in progress) will be DD
92 Toyota Land Cruiser 4x4 monster (heavily modified)
build thread on mud http://forum.ih8mud.com/80-series-tech/288587-rotf-lt1fire.html

84 K1500 GMC Suburban 6.2 diesel motor...... dying to offer its engine to the Land Cruiser

Hi all, wonderful thread. Getting ready to install a non-OD 5 speed in my '87 300d and the info shared here is much appreciated.

In regards to the comments of rough/jerky shifting, has anyone tried adjusting the injector pump to help smooth out the shifting? According to the "Bosch M and MW pump theory" document (sorry, don't have a link handy), a clockwise adjustment to the vertical throttle stop will increase the time taken for the engine to return to idle so, to quote the author, "...you can set the return to Idle rate to match the shift time, so when you are ready to let the clutch back out, the engine is at the same speed as the transmission and clutch disc, creating a very smooth shift.".

The stock manual 603s had an additional electric actuator for this. Not sure what it did exactly.

http://www.peachparts.com/shopforum/mercedes-cars-sale/326304-87-300d-5-spd-short-sale.html#post3019163

I'm looking to get rid of it

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08 R320 CDI current

Past
95 E420
87 300D Turbo 5spd
90 300TE
83 300SD
85 300TD
92 400E
85 190D

ashed are u still around I would like to ask you a few questions

I'll update this thread and state that third gear on the 717.41x gearboxes is pretty weak. I know of atleast 3 trans that lost third gear. Everyone running 300+hp.

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http://superturbodiesel.com/images/sig.04.10.jpg
1995 E420 Schwarz
1995 E300 Weiss
#1987 300D Sturmmachine
#1991 300D Nearly Perfect
#1994 E320 Cabriolet
#1995 E320 Touring
#1985 300D Sedan
OBK #42