Greg,

Congrats on your repair. My 190D 2.2 may be facing the same repair shortly. With a whopping 70-ish HP available from the NA 2.2L Diesel, my clutch gets abused a bit.

You would think with the popularity of the W201 series cars abroad, there would be a surplus of clutches and flywheels abroad.

Hopefully, my 1984 car has a single mass flywheel that can be machined.

Sholin

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What else, '73 MB 280 SEL (Lt Blue)
Daily driver: '84 190D 2.2 5 spd.

Sholin,

Your '84 should not have a dual mass flywheel as they were not introduced until about '89. For that matter, I am unsure if the diesels ever got them.

Unless your flywheel is damaged through overheating or scored due to the clutch wearing below the rivets, it is unlikely it will require machining. Being a conventional flywheel it can be machined unlike the dual mass versions. Even if it requires replacement due to excessive damage, it will only be a fraction of the price of a dual mass version.

Are you attempting the clutch replacement yourself? Whilst I was perfectly comfortable with tackling the job, I was not looking forward to it after hearing how difficult access to some of the bolts around the bell-housing can be. I was also not looking forward to having to remove the entire exhaust system and heat shields to access and loosen the centre tailshaft joint as recommended in workshop manuals. As it turned out, I got away with only removing the rubber rings from the exhaust allowing it to drop down at the rear and allowing the engine and transmission to tilt back. I was able to slide the front section of the tailshaft back enough to disengage it from the rear of the transmission without having to remove it or having to access the centre joint (therefore not having to remove heat shields). Apparently models of this era do not tightly clamp the forward section of the tailshaft at the centre joint which means it can slide back and forth.

With the transmission tilted back, accessing bell-housing bolts was easy enough by way of numerous 1/2" drive socket extensions joined together and passed over the top of the transmission from the rear. Whilst I man-handled the transmission to remove it (it "only" weighs about 30kg or 66lbs and my chest broke its fall!) refitting it required the use of a floor jack. Ensure you borrow or make a tool to centre the clutch plate as even with this tool it was tricky to get the geabox input shaft to locate correctly whilst trying to balance the transmission on the floor jack. Incidentally, I had both the front and rear of the car raised on ramps and stands with enough room underneath to get the transmission out.

Good luck,
Greg

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107.023: 350SLC, 3-speed auto, icon gold, parchment MBtex (sold 2012 after 29 years ownership).
107.026: 500SLC, 4-speed auto, thistle green, green velour.
124.090: 300TE, 4-speed auto, arctic white, cream-beige MBtex.
201.028: 190E 2.3 Sportline, 5-speed manual, arctic white, blue leather.
201.028: 190E 2.3, 4-speed auto, blue-black, grey MBtex.
201.034: 190E 2.3-16, 5-speed manual, blue-black, black leather.

Greg,

I had something similar happen to my 240D about 15 years ago. The clutch would intermittently not release and after disassembly found one of the pressure plate fingers broken off and floating around causing havoc. Pressure plate, clutch plate and throwout bearing and I was good to go.

Glad you got her all back together. Life without a stick shift car to drive is almost not worth living.

ive personaly seen a clutch let go and bash threw a steel bell houesing with ease enough to penatrate the floor and up into the dash on a dodge pickup that wasint very modified . so the aluminum on the 5 speed w201 bellhouesing wouldint be even a match for a clutch flying apart . also herd of many injurys from this happining .

and i can say that the bell houesing bolts are a major hassel to get to on both the automatic and the 5 speeds .i am changin my 88 w201 over from auto to 5 speed also using a sachs drivin plate , preasure plate and throw out bearing . glad to see there are geting to be more people interested in 5 speed 190's ! as soon as i get a flywheel for my benz ill be back on the road .

also would an 85 flywheel fit an 88' 2.3 engine and an 87 clutch and preasure plate ? i bought the kit for my old flywheel and come to find out that its totaly un usable . i dont want to go through another 2 weeks or more waiting for another clutch kit to be deliverd , so i was woundering if itd fit on an 85 flywheel that a local wrecking yard has . thanks in advance for any help .

,Justin aka: mbluvrr


shifting isint just fun , its fuuunnnn!!!!

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mercedes = performance with lots of comfort !