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View Poll Results: Manual transmission Shift Assembly rebuild video?
Yes 32 100.00%
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Voters: 32. You may not vote on this poll

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  #1  
Old 03-01-2013, 10:23 AM
whunter's Avatar
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Join Date: Dec 2003
Location: Metro Detroit, Michigan
Posts: 17,357
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.


.
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1973 300D
1973 309D - stolen
1978 280SE
1980 240D
1983 300D
1984 190D
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  #2  
Old 03-01-2013, 01:31 PM
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Join Date: Apr 2005
Location: Cicero, Hamilton County, Indiana about 30 miles north of downtown Indianapolis
Posts: 2,619
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
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Junqueyardjim
Christianity, if false, is of no importance, and if true, of infinite importance. The only thing it cannot be is moderately important. C.S. Lewis



1983 Mercedes W123 240D 4 Speed 285,000 on the road with a 617 turbo, beautiful butter yellow, license plate # 83 240D INDIANA

2003 Jaguar Type X, AWD. beautiful, good mileage,
Mom's car, but I won't let her drive it!
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  #3  
Old 03-01-2013, 05:34 PM
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Location: Metro Detroit, Michigan
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OK

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

.
__________________
ASE Master Mechanic
asemastermechanic@juno.com

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.
Prototype Vehicle build.
Prototype Fleet Durability
Prototype vehicle instrumentation.
Technical Quality Auditor.
Automotive Technical Writer

1973 300D
1973 309D - stolen
1978 280SE
1980 240D
1983 300D
1984 190D
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  #4  
Old 03-02-2013, 12:12 AM
Stugist's Avatar
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Join Date: Apr 2012
Location: Western Washington, USA
Posts: 118
Question; Would this be like a before/after video, or a more in-depth how-to?

If the latter, YES PLEASE!
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- 1979 W123 240D 4-speed, 390k miles
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  #5  
Old 04-14-2013, 08:29 PM
whunter's Avatar
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Join Date: Dec 2003
Location: Metro Detroit, Michigan
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OK

Quote:
Originally Posted by whunter View Post
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.


.
__________________
ASE Master Mechanic
asemastermechanic@juno.com

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.
Prototype Vehicle build.
Prototype Fleet Durability
Prototype vehicle instrumentation.
Technical Quality Auditor.
Automotive Technical Writer

1973 300D
1973 309D - stolen
1978 280SE
1980 240D
1983 300D
1984 190D
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  #6  
Old 04-14-2013, 08:30 PM
whunter's Avatar
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Join Date: Dec 2003
Location: Metro Detroit, Michigan
Posts: 17,357
I pinched the rubber boot with my fingers, and pulled the bottom loose.















__________________
ASE Master Mechanic
asemastermechanic@juno.com

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.
Prototype Vehicle build.
Prototype Fleet Durability
Prototype vehicle instrumentation.
Technical Quality Auditor.
Automotive Technical Writer

1973 300D
1973 309D - stolen
1978 280SE
1980 240D
1983 300D
1984 190D

Last edited by whunter; 05-12-2013 at 11:59 AM.
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  #7  
Old 04-14-2013, 08:30 PM
whunter's Avatar
Moderator
 
Join Date: Dec 2003
Location: Metro Detroit, Michigan
Posts: 17,357
























__________________
ASE Master Mechanic
asemastermechanic@juno.com

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.
Prototype Vehicle build.
Prototype Fleet Durability
Prototype vehicle instrumentation.
Technical Quality Auditor.
Automotive Technical Writer

1973 300D
1973 309D - stolen
1978 280SE
1980 240D
1983 300D
1984 190D

Last edited by whunter; 04-14-2013 at 08:52 PM.
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  #8  
Old 04-14-2013, 08:30 PM
whunter's Avatar
Moderator
 
Join Date: Dec 2003
Location: Metro Detroit, Michigan
Posts: 17,357











__________________
ASE Master Mechanic
asemastermechanic@juno.com

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.
Prototype Vehicle build.
Prototype Fleet Durability
Prototype vehicle instrumentation.
Technical Quality Auditor.
Automotive Technical Writer

1973 300D
1973 309D - stolen
1978 280SE
1980 240D
1983 300D
1984 190D

Last edited by whunter; 04-14-2013 at 10:31 PM.
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  #9  
Old 04-14-2013, 08:30 PM
whunter's Avatar
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Join Date: Dec 2003
Location: Metro Detroit, Michigan
Posts: 17,357


































__________________
ASE Master Mechanic
asemastermechanic@juno.com

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.
Prototype Vehicle build.
Prototype Fleet Durability
Prototype vehicle instrumentation.
Technical Quality Auditor.
Automotive Technical Writer

1973 300D
1973 309D - stolen
1978 280SE
1980 240D
1983 300D
1984 190D

Last edited by whunter; 04-14-2013 at 10:28 PM.
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  #10  
Old 04-14-2013, 08:30 PM
whunter's Avatar
Moderator
 
Join Date: Dec 2003
Location: Metro Detroit, Michigan
Posts: 17,357












__________________
ASE Master Mechanic
asemastermechanic@juno.com

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.
Prototype Vehicle build.
Prototype Fleet Durability
Prototype vehicle instrumentation.
Technical Quality Auditor.
Automotive Technical Writer

1973 300D
1973 309D - stolen
1978 280SE
1980 240D
1983 300D
1984 190D

Last edited by whunter; 04-14-2013 at 10:24 PM.
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  #11  
Old 04-14-2013, 08:31 PM
whunter's Avatar
Moderator
 
Join Date: Dec 2003
Location: Metro Detroit, Michigan
Posts: 17,357








.
__________________
ASE Master Mechanic
asemastermechanic@juno.com

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.
Prototype Vehicle build.
Prototype Fleet Durability
Prototype vehicle instrumentation.
Technical Quality Auditor.
Automotive Technical Writer

1973 300D
1973 309D - stolen
1978 280SE
1980 240D
1983 300D
1984 190D

Last edited by whunter; 04-14-2013 at 10:31 PM.
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  #12  
Old 04-14-2013, 09:06 PM
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Join Date: May 2007
Location: Out in the Boonies of Hot, Dry, Dusty, Windy Nevada
Posts: 9,585
Do I need my Captin Midnight Super Decoder Ring to decode these last 5 Posts?


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
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  #13  
Old 04-14-2013, 10:29 PM
whunter's Avatar
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Join Date: Dec 2003
Location: Metro Detroit, Michigan
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Chuckle

Quote:
Originally Posted by charmalu View Post
Do I need my Captin Midnight Super Decoder Ring to decode these last 5 Posts?


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

.
__________________
ASE Master Mechanic
asemastermechanic@juno.com

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.
Prototype Vehicle build.
Prototype Fleet Durability
Prototype vehicle instrumentation.
Technical Quality Auditor.
Automotive Technical Writer

1973 300D
1973 309D - stolen
1978 280SE
1980 240D
1983 300D
1984 190D
Reply With Quote
  #14  
Old 04-14-2013, 10:45 PM
Registered User
 
Join Date: May 2007
Location: Out in the Boonies of Hot, Dry, Dusty, Windy Nevada
Posts: 9,585
Ok, understand. Forgot where I put my ring anyway.

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
__________________
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
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  #15  
Old 04-15-2013, 05:19 AM
whunter's Avatar
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Join Date: Dec 2003
Location: Metro Detroit, Michigan
Posts: 17,357
Yep

Quote:
Originally Posted by charmalu View Post
Ok, understand. Forgot where I put my ring anyway.

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.

.
__________________
ASE Master Mechanic
asemastermechanic@juno.com

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.
Prototype Vehicle build.
Prototype Fleet Durability
Prototype vehicle instrumentation.
Technical Quality Auditor.
Automotive Technical Writer

1973 300D
1973 309D - stolen
1978 280SE
1980 240D
1983 300D
1984 190D

Last edited by whunter; 05-12-2013 at 12:02 PM.
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