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  #1  
Old 06-20-2015, 08:18 AM
gatorblue92's Avatar
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Join Date: Jan 2006
Location: Delaware
Posts: 3,358
My ongoing 300TE project

Since my 300TE is about to undergo a major project I thought it was time to start a build thread.

In the past year plus I have owned the car I haven't really done much aside from some small improvements and routine maintenance like tires, brakes and oil changes but since the car stranded me on Thursday its time for some major work.

Here is Chad's original thread on the wagon.
Still in the diesel family ... but



Chad's improvements.




First day home with me


New radio.


Euro Headlights


Road trips to North Carolina, Tennessee and Alabama






__________________
1977 MB 240D 4 speed 145K - Nearly Perfect
1993 MB 400E 212K - New Project
2014 Honda CR-V 85K - Wife's DD
2018 Ford F150 5.slow 15K - My DD

1979 MB 280E 90K - Sold
1983 MB 240D 238K - Scrapped
1984 MB 300D 347K? - Sold
1984 MB 300TD Wagon - 188k - Sold
1987 MB 300E 5 speed 258K - Scrapped
1991 MB 300TE 5 speed 276K - Sold
1993 MB 400E 130K - Sold
1995 MB E320 Wagon 190k - Sold

Last edited by gatorblue92; 06-20-2015 at 08:34 AM.
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  #2  
Old 06-20-2015, 08:24 AM
gatorblue92's Avatar
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Join Date: Jan 2006
Location: Delaware
Posts: 3,358
Over the past two months the transmission has been acting up and on my way to work this past Thursday it finally lost all forward gears. I thought about getting a Sun Valley rebuild but i have one of these just sitting there so my 300TE is getting a 5 speed manual.

__________________
1977 MB 240D 4 speed 145K - Nearly Perfect
1993 MB 400E 212K - New Project
2014 Honda CR-V 85K - Wife's DD
2018 Ford F150 5.slow 15K - My DD

1979 MB 280E 90K - Sold
1983 MB 240D 238K - Scrapped
1984 MB 300D 347K? - Sold
1984 MB 300TD Wagon - 188k - Sold
1987 MB 300E 5 speed 258K - Scrapped
1991 MB 300TE 5 speed 276K - Sold
1993 MB 400E 130K - Sold
1995 MB E320 Wagon 190k - Sold
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  #3  
Old 06-20-2015, 08:32 AM
gatorblue92's Avatar
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Join Date: Jan 2006
Location: Delaware
Posts: 3,358
I haven't started any work on the 300TE yet but I have already removed nearly everything I will need from the parts car. I'm going to install a new clutch, pressure plate, pilot bearing, throwout bearing, master cylinder, slave cylinder, flex disks, driveshaft center bushing and rear main seal for the engine.

I'm going to update this post with part numbers for anyone else who will be following along.

Sachs Clutch Kit KF66301
__________________
1977 MB 240D 4 speed 145K - Nearly Perfect
1993 MB 400E 212K - New Project
2014 Honda CR-V 85K - Wife's DD
2018 Ford F150 5.slow 15K - My DD

1979 MB 280E 90K - Sold
1983 MB 240D 238K - Scrapped
1984 MB 300D 347K? - Sold
1984 MB 300TD Wagon - 188k - Sold
1987 MB 300E 5 speed 258K - Scrapped
1991 MB 300TE 5 speed 276K - Sold
1993 MB 400E 130K - Sold
1995 MB E320 Wagon 190k - Sold
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  #4  
Old 06-20-2015, 08:52 AM
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Join Date: Dec 2011
Location: Norwalk, CT
Posts: 163
If you ever have the chance or inclination, OEM 500e springs work great on wagons. Slight drop and firmer ride. H&Rs are crap by comparison.
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  #5  
Old 06-25-2015, 05:56 AM
gatorblue92's Avatar
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Location: Delaware
Posts: 3,358
I'm keeping the stock height on this one. My now departed 300E was lowered and I loved the way it looked but the harsh ride started to bother my back towards the end.

My clutch kit came in yesterday and I'm currently waiting on the hydraulic bits and the rear main seal to arrive.
__________________
1977 MB 240D 4 speed 145K - Nearly Perfect
1993 MB 400E 212K - New Project
2014 Honda CR-V 85K - Wife's DD
2018 Ford F150 5.slow 15K - My DD

1979 MB 280E 90K - Sold
1983 MB 240D 238K - Scrapped
1984 MB 300D 347K? - Sold
1984 MB 300TD Wagon - 188k - Sold
1987 MB 300E 5 speed 258K - Scrapped
1991 MB 300TE 5 speed 276K - Sold
1993 MB 400E 130K - Sold
1995 MB E320 Wagon 190k - Sold
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  #6  
Old 06-30-2015, 08:21 PM
gatorblue92's Avatar
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Join Date: Jan 2006
Location: Delaware
Posts: 3,358
Made some major progress over the past few days.

Got the auto out.







Discovered the source of my driveshaft vibration

__________________
1977 MB 240D 4 speed 145K - Nearly Perfect
1993 MB 400E 212K - New Project
2014 Honda CR-V 85K - Wife's DD
2018 Ford F150 5.slow 15K - My DD

1979 MB 280E 90K - Sold
1983 MB 240D 238K - Scrapped
1984 MB 300D 347K? - Sold
1984 MB 300TD Wagon - 188k - Sold
1987 MB 300E 5 speed 258K - Scrapped
1991 MB 300TE 5 speed 276K - Sold
1993 MB 400E 130K - Sold
1995 MB E320 Wagon 190k - Sold
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  #7  
Old 06-30-2015, 08:34 PM
gatorblue92's Avatar
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Join Date: Jan 2006
Location: Delaware
Posts: 3,358
Had an unexpected day off work today due to a water main break by my office so I put my time to good use.

I pretty much finished everything inside the car including the wiring for the reverse lights and bypassing the neutral safety switch along with all of the plumbing for the clutch. I'm pretty pleased with my progress but a bit annoyed that I'm waiting until next Monday for the order I placed from the house of autos in Arizona... As an aside the parts I ordered from Pelican came within 3 days. They are not always the cheapest but they are the quickest. Anyway on with some pictures.

Got the Flywheel back.




Getting somewhere.







All done inside the car.



Another annoyance I ran into was a stripped out bolt on the exhaust downpipe to manifold connection. I had to remove the exhaust manifolds to get enough room to get in there and grind the bolt head off. Thankfully I have another set of manifolds so I decided to paint them while they were off.

__________________
1977 MB 240D 4 speed 145K - Nearly Perfect
1993 MB 400E 212K - New Project
2014 Honda CR-V 85K - Wife's DD
2018 Ford F150 5.slow 15K - My DD

1979 MB 280E 90K - Sold
1983 MB 240D 238K - Scrapped
1984 MB 300D 347K? - Sold
1984 MB 300TD Wagon - 188k - Sold
1987 MB 300E 5 speed 258K - Scrapped
1991 MB 300TE 5 speed 276K - Sold
1993 MB 400E 130K - Sold
1995 MB E320 Wagon 190k - Sold
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  #8  
Old 07-01-2015, 08:26 AM
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Looks great. Keep it up and keep the pics and updates coming!
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  #9  
Old 07-02-2015, 05:51 AM
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Join Date: Jan 2006
Location: Delaware
Posts: 3,358
Only got to spend a few minutes on the car last night but I did get the rear main seal changed. The dealer had one in stock when I went to pick up my rear flex disk so I grabbed one.



__________________
1977 MB 240D 4 speed 145K - Nearly Perfect
1993 MB 400E 212K - New Project
2014 Honda CR-V 85K - Wife's DD
2018 Ford F150 5.slow 15K - My DD

1979 MB 280E 90K - Sold
1983 MB 240D 238K - Scrapped
1984 MB 300D 347K? - Sold
1984 MB 300TD Wagon - 188k - Sold
1987 MB 300E 5 speed 258K - Scrapped
1991 MB 300TE 5 speed 276K - Sold
1993 MB 400E 130K - Sold
1995 MB E320 Wagon 190k - Sold
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  #10  
Old 07-02-2015, 07:41 AM
Stretch's Avatar
...like a shield of steel
 
Join Date: Sep 2009
Location: Somewhere in the Netherlands
Posts: 14,453
Nice to see the flywheel will only go on one way!
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1992 W201 190E 1.8 171,000 km - Daily driver
1981 W123 300D ~ 100,000 miles / 160,000 km - project car stripped to the bone
1965 Land Rover Series 2a Station Wagon CIS recovery therapy!
1961 Volvo PV544 Bare metal rat rod-ish thing

I'm here to chat about cars and to help others - I'm not here "to always be right" like an internet warrior



Don't leave that there - I'll take it to bits!
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  #11  
Old 07-02-2015, 09:46 AM
Simpler=Better's Avatar
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Location: Baltimore, MD
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Looks good!

Wrap the exhaust manifold while they're off. I typically use the el cheapo stuff, but the word on the street is that DEI wrap is the cat's meow.
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$60 OM617 Blank Exhaust Flanges
$110 OM606 Blank Exhaust Flanges
No merc at the moment
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  #12  
Old 07-05-2015, 07:12 AM
gatorblue92's Avatar
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Join Date: Jan 2006
Location: Delaware
Posts: 3,358
Got everything finished up yesterday morning and drove the car a bit in the afternoon and its like driving a totally different car. Someone mentioned that it would feel different than the 300E sedan due to the different final drive ratio and they were right. At 70 MPH the engine sits at 2200 RPM which is down from the 2500 RPM in the sedan and 3000 RPM when the wagon had the automatic. I'm hoping for a dramatic rise in MPG on the highway. The different shift points will take a bit of getting accustomed to but I'm very pleased with results. I have some pictures I need to upload but my camera cable is currently AWOL.
__________________
1977 MB 240D 4 speed 145K - Nearly Perfect
1993 MB 400E 212K - New Project
2014 Honda CR-V 85K - Wife's DD
2018 Ford F150 5.slow 15K - My DD

1979 MB 280E 90K - Sold
1983 MB 240D 238K - Scrapped
1984 MB 300D 347K? - Sold
1984 MB 300TD Wagon - 188k - Sold
1987 MB 300E 5 speed 258K - Scrapped
1991 MB 300TE 5 speed 276K - Sold
1993 MB 400E 130K - Sold
1995 MB E320 Wagon 190k - Sold
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  #13  
Old 07-05-2015, 08:25 AM
JB3 JB3 is offline
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A job well done!
Rear main seal looks like a real pleasure compared to the OM61X
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  #14  
Old 07-05-2015, 08:55 AM
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Posts: 242
You are living my fantasy!
Bring it for Chad's GTG this summer.
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  #15  
Old 07-05-2015, 04:40 PM
gatorblue92's Avatar
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Join Date: Jan 2006
Location: Delaware
Posts: 3,358
Quote:
Originally Posted by JB3 View Post
A job well done!
Rear main seal looks like a real pleasure compared to the OM61X
Thanks! The rear main took all of 5 minutes to change out and 90% of that time was prepping the engine block surface for the new RTV sealant.


Quote:
Originally Posted by professor View Post
You are living my fantasy!
Bring it for Chad's GTG this summer.
It will be there!

I drove it again this morning and it does have some other issues I need to sort out. If I disengage the clutch to shift into neutral while I'm going 35mph+ the engine will stall. Not sure what the cause of that is yet.
__________________
1977 MB 240D 4 speed 145K - Nearly Perfect
1993 MB 400E 212K - New Project
2014 Honda CR-V 85K - Wife's DD
2018 Ford F150 5.slow 15K - My DD

1979 MB 280E 90K - Sold
1983 MB 240D 238K - Scrapped
1984 MB 300D 347K? - Sold
1984 MB 300TD Wagon - 188k - Sold
1987 MB 300E 5 speed 258K - Scrapped
1991 MB 300TE 5 speed 276K - Sold
1993 MB 400E 130K - Sold
1995 MB E320 Wagon 190k - Sold
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