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-   -   Manual transmission 240D Shifter Assembly rebuild? (http://www.peachparts.com/shopforum/general-information/335351-manual-transmission-240d-shifter-assembly-rebuild.html)

whunter 03-01-2013 10:23 AM

Manual transmission 240D Shifter Assembly rebuild?
 
I am preparing to rebuild - refresh my 1980 240D manual transmission (floor) Shift lever Assembly.

The floor shift lever is slopping around = difficult going from 2-3 over to 3-4.


.

junqueyardjim 03-01-2013 01:31 PM

I rebuilt mine when I put the 617 into my 240D. I found it quit easy using only a couple new internal parts. The problem I found before I drove the car was that the plastic body that contains this line up of parts had been pretty badly damaged from underneath the car. It probably still shifted. But I used this diagram of the parts to reassemble it and it went well and easy. Then I made the 6mm key to properly adjust the rods by cutting the head off a long 6mm bolt, then cut the threaded part from the un-threaded part, then welded them together at 90 degrees. I also did grind just a little point to the un-threaded end to get it to slide in a little easier.

http://mb.ilcats.ru/part/class/1/ccode/F/cat/68K/type/123/subtype/123/group/26

whunter 03-01-2013 05:34 PM

OK
 
The parts arrived.
I will try to get this done in the next week.

.

Stugist 03-02-2013 12:12 AM

Question; Would this be like a before/after video, or a more in-depth how-to?

If the latter, YES PLEASE!

whunter 04-14-2013 08:29 PM

OK
 
Quote:

Originally Posted by whunter (Post 3107847)
The parts arrived.
I will try to get this done in the next week.

.

This is my daily driver.
The failure was sudden, no time for video.
As a momentary solution, I am posting cell phone pictures of what I encountered.

FYI:
The second gear synchromesh must be replaced soon, and I will see about doing this shift lever video then.


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whunter 04-14-2013 08:30 PM

I pinched the rubber boot with my fingers, and pulled the bottom loose.

http://i21.photobucket.com/albums/b2...psf665a83e.jpg

http://i21.photobucket.com/albums/b2...psbd5f8de2.jpg

http://i21.photobucket.com/albums/b2...ps706d87da.jpg

http://i21.photobucket.com/albums/b2...ps50f35800.jpg

http://i21.photobucket.com/albums/b2...ps4dd585cf.jpg

http://i21.photobucket.com/albums/b2...psac3393a6.jpg

http://i21.photobucket.com/albums/b2...psaeacc5d2.jpg

http://i21.photobucket.com/albums/b2...ps2e2b18c4.jpg

whunter 04-14-2013 08:30 PM

http://i21.photobucket.com/albums/b2...ps7c5ff6e4.jpg

http://i21.photobucket.com/albums/b2...ps8465ccfc.jpg

http://i21.photobucket.com/albums/b2...ps9f875522.jpg

http://i21.photobucket.com/albums/b2...ps81eb8f9f.jpg

http://i21.photobucket.com/albums/b2...ps8ad6af85.jpg

http://i21.photobucket.com/albums/b2...psc0e79e86.jpg

http://i21.photobucket.com/albums/b2...ps75503f21.jpg

http://i21.photobucket.com/albums/b2...pse715ace7.jpg

http://i21.photobucket.com/albums/b2...psd71f4f5a.jpg

http://i21.photobucket.com/albums/b2...ps598afc2e.jpg

http://i21.photobucket.com/albums/b2...ps7a9e0d77.jpg

http://i21.photobucket.com/albums/b2...ps1abc4d06.jpg

http://i21.photobucket.com/albums/b2...ps88e5b007.jpg

whunter 04-14-2013 08:30 PM

http://i21.photobucket.com/albums/b2...ps81c3801f.jpg

http://i21.photobucket.com/albums/b2...pscb54cca9.jpg

http://i21.photobucket.com/albums/b2...ps86daf1a5.jpg

http://i21.photobucket.com/albums/b2...ps114d8fa6.jpg

http://i21.photobucket.com/albums/b2...ps7d14fdb1.jpg


http://i21.photobucket.com/albums/b2...pscc30935e.jpg

whunter 04-14-2013 08:30 PM

http://i21.photobucket.com/albums/b2...ps32d160f0.jpg

http://i21.photobucket.com/albums/b2...psbb9b45a6.jpg

http://i21.photobucket.com/albums/b2...psef07c5b6.jpg

http://i21.photobucket.com/albums/b2...ps7e1a1510.jpg

http://i21.photobucket.com/albums/b2...ps66b8b90a.jpg

http://i21.photobucket.com/albums/b2...ps466b90ff.jpg

http://i21.photobucket.com/albums/b2...ps6a84cbec.jpg

http://i21.photobucket.com/albums/b2...ps01be6637.jpg

http://i21.photobucket.com/albums/b2...ps8e013e2b.jpg

http://i21.photobucket.com/albums/b2...ps046ff3c1.jpg

http://i21.photobucket.com/albums/b2...psaa4a6cf9.jpg

http://i21.photobucket.com/albums/b2...ps007f6ffc.jpg

http://i21.photobucket.com/albums/b2...ps01a51114.jpg

http://i21.photobucket.com/albums/b2...ps18b0f2b2.jpg

http://i21.photobucket.com/albums/b2...ps46be73ec.jpg

http://i21.photobucket.com/albums/b2...ps8269b6ba.jpg

http://i21.photobucket.com/albums/b2...ps2c7ff433.jpg

http://i21.photobucket.com/albums/b2...ps9264a880.jpg

whunter 04-14-2013 08:30 PM

http://i21.photobucket.com/albums/b2...psec47805b.jpg

http://i21.photobucket.com/albums/b2...ps8c1607be.jpg

http://i21.photobucket.com/albums/b2...ps7eb065dd.jpg

http://i21.photobucket.com/albums/b2...ps5b9f95aa.jpg

http://i21.photobucket.com/albums/b2...ps8fb23913.jpg

http://i21.photobucket.com/albums/b2...pse6c131a6.jpg

http://i21.photobucket.com/albums/b2...psbd5f8de2.jpg

whunter 04-14-2013 08:31 PM

http://i21.photobucket.com/albums/b2...ps02433d4f.jpg

http://i21.photobucket.com/albums/b2...ps047cb0b3.jpg

http://i21.photobucket.com/albums/b2...ps4ec197f8.jpg

http://i21.photobucket.com/albums/b2...ps26ca3ea3.jpg

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charmalu 04-14-2013 09:06 PM

Do I need my Captin Midnight Super Decoder Ring to decode these last 5 Posts? :D


Charlie

whunter 04-14-2013 10:29 PM

Chuckle
 
Quote:

Originally Posted by charmalu (Post 3131152)
Do I need my Captin Midnight Super Decoder Ring to decode these last 5 Posts? :D


Charlie

No decoder ring needed. :)
It takes a few minutes to add the picture links. :)

.

charmalu 04-14-2013 10:45 PM

Ok, understand.:) Forgot where I put my ring anyway.:rolleyes:

I took one of these apart several years ago to clean out the old grease and crap spilt on it from the top, and them re-lube it.
the most difficult part, as I remember, was getting those 2 springy washers back in, and it all back together.


I bought one of those shift boots to replace the original one that was is really bad shape. the new one was made in India, and is the stiffest piece of plastic &^%$. when it is cold, it makes it hard to shift, and the thing won`t stay under the groove on the shifter plate.

I found a leather one off a 96 Saab a few days ago, Iam going to retrofit. I have a spare black plastic shifter plate from PNP I will use.

Charlie

whunter 04-15-2013 05:19 AM

Yep
 
Quote:

Originally Posted by charmalu (Post 3131188)
Ok, understand.:) Forgot where I put my ring anyway.:rolleyes:

I took one of these apart several years ago to clean out the old grease and crap split on it from the top, and them re-lube it.
the most difficult part, as I remember, was getting those 2 springy washers back in, and it all back together.


I bought one of those shift boots to replace the original one that was is really bad shape. the new one was made in India, and is the stiffest piece of plastic &^%$. when it is cold, it makes it hard to shift, and the thing won`t stay under the groove on the shifter plate.

I found a leather one off a 96 Saab a few days ago, I am going to retrofit. I have a spare black plastic shifter plate from PNP I will use.

Charlie

Mine had a cheap MTC shift boot, it survived three months and split.
The new shift boot is Mercedes STAR marked, much more flexible.

.


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