Hi, my 1994 Mercedes E320 wagon was so much damaged due to flex disc failures that caused a chain reaction of other nearby parts to be replace and/or repair that I had to tow the wagon to a reputable Mercedes Repair center in Nashville.

After diagnosing the issues, the shop foreman recommended to a mercedes certified body shop repair to replace the transmission tunnel or any other name by welding. I never heard of this transmission tunnel replacement. This is way out of my league when it comes to knowledge and skill level. I tried to research this issue and so far nothing really stands out. Does anyone out there knows about this kind of thing? What kind of steps does this involve? What is the approximate total cost of this particular repair and replace the transmission tunnel? Comments, feedback, advice is greatly appreciated. Thanks to all for reading.

Offhand, I'd say that the cost to return this car to the road greatly exceeds it's value.

The tunnel is the central part of the floorpan. First thought is that this may be cosmetic, there might be alternatives that are more cost effective. For example, if the sheetmetal is damaged, can a small replacement panel be riveted in to replace damaged section.

If replacement is desired, consider that the entire interior may need to be removed (A pillar to B pillar). Certainly seats, carpet, console, and probably underdash HVAC and accelerator pedal. Lots of labor here.

Unless there is a great emotional tie to the car, I'd be inclined to let this one go.

Jim

__________________
14 E250 BlueTEC black. 45k miles
95 E320 Cabriolet Emerald green 66k miles
94 E320 Cabriolet Emerald green 152k miles
85 300TD 4 spd man, euro bumpers and lights, 15" Pentas dark blue 274k miles

Could you post pictures of the damaged tunnel? We may be able to offer suggestions.

Good luck!!!

__________________
"Rudeness is a weak man's imitation of strength" - Eric Hoffer

the good thing about your situation is that this area of the car is not really visible so you can just cut out the "twisted" metal and weld new metal in there or find a shop that would do it.

dmorgan, for a failed flex disc to cause substantial damage in a brief amount of time I would suspect the transmission tunnel is heavily rusted. Therefore, it would not warrant spending a considerable amount of money to repair your 1994 E320 wagon.

__________________
Fred Hoelzle

Pictures would help us give informed opinions.

__________________
[SIGPIC] Diesel loving autocrossing grandpa Architect. 08 Dodge 3/4 ton with Cummins & six speed; I have had about 35 benzes. I have a 39 Studebaker Coupe Express pickup in which I have had installed a 617 turbo and a five speed manual.[SIGPIC]

..I also have a 427 Cobra replica with an aluminum chassis.

Pure speculation on my part, but it could be that the area where the driveshaft carrier bearing mounts to the floor pan was damaged and the bearing is now misaligned; agreed that photos would be very helpful - it could be that all you need is a carefully calibrated sledgehammer.

Best Regards,
Rob

__________________
Robert Fini

'12 ML350 BlueTec, 87k
'06 E320CDI, 270k
'05 T1N Sprinter 2500/Pleasure-Way Plateau TS, 69k
'97 C36AMG, 313k (son's)
'94 E320T, 249k
'93 190E Sportline LE, 168k (daughter's)
'84 190E-2.3/5spd (Stage Rally Racer)
'66 230 W110 Sedan (Barn Find, Vintage Racer build in progress)

This is what I am thinking.

__________________
[SIGPIC] Diesel loving autocrossing grandpa Architect. 08 Dodge 3/4 ton with Cummins & six speed; I have had about 35 benzes. I have a 39 Studebaker Coupe Express pickup in which I have had installed a 617 turbo and a five speed manual.[SIGPIC]

..I also have a 427 Cobra replica with an aluminum chassis.

JimFreeh, Sugar Bear, christuna, Ferdman, t walgamuth and RobertFini, thank you for all of your excellent comments, advice and feedback. As for those who asked for pictures of the location of the undercarriage on my 1994 Mercedes E320 wagon, I was unabled to do so due to the fact the Mercedes is now in the shop.

I wanted to get to the bottom of the issue with a clear cut understanding and exactly what is going on. So I was abled to contact the shop foreman and asked him explain specifically and tell me exactly what needs to be done on the transmission tunnel repair? His response was the tunnel above the transmission at the end of the tail shaft above where the front drive shaft attaches to the transmission. The tunnel can be replaced separately, the backing of the carpet is visible through the grooves cut in the tunnel. It does also house the muffler hanger support as well, with the tunnel being damaged to the point of being able to see the backing of the carpet it needs to be replaced. It can be cut out and a new one welded in.

In addition, I asked for further details on the subject matter. His response to that was the transmission tunnel is a separate piece that can be cut out and the new one welded in, the part number for the tunnel is 124 610 06 71. The tunnel covers the entire area over the transmission from the bulk head (fire wall) to right where the drive shaft attaches to the transmission output shaft yoke.


Does this above explanation of the issue make any sense at all?

Any comments, feedback and/or advice on the latest development is greatly appreciated. Thanks to all for reading.

Thanks for explaining, dmorgan; it sounds like the front end of the driveshaft at the transmission output came loose and was flailing about wildly within the tunnel.

Genuine Mercedes Parts dot Com (discount online parts outlet for Mercedes-Benz of Alpharetta, GA) shows this part number for the tunnel at $248 brand new, but the real expense is going to be in the labor to get the old one exposed and cut out and then the new one welded in, painted and then reassembled.

I'd recommend that you take it to a proper body shop for a cost estimate unless you "know a guy." There are those who will say the cost isn't worth it, but that decision is up to you - best of luck with it.

Best Regards,
Rob

__________________
Robert Fini

'12 ML350 BlueTec, 87k
'06 E320CDI, 270k
'05 T1N Sprinter 2500/Pleasure-Way Plateau TS, 69k
'97 C36AMG, 313k (son's)
'94 E320T, 249k
'93 190E Sportline LE, 168k (daughter's)
'84 190E-2.3/5spd (Stage Rally Racer)
'66 230 W110 Sedan (Barn Find, Vintage Racer build in progress)

RobertFini, thank you for your last post. Now the bad news.

The Service Manager got in touch with me.

He basically said it looks like they have hit a dead end on repairs. They were not able to locate the transmission tunnel replacement part for the body shop to replace and he heard from them this afternoon that they are not able to locate the part either. All sources say the part is either no longer available or on backorder with no ETA. Without the availability of the part to weld into place, the car is not structurally sound and can not be repaired. Even if the part was available, the cost to repair was going to well exceed the value of the car deeming the repair not advisable.

I am exploring what available options I have now.

Sell individual parts and junk the car?

Hang on the car and do little by little doing the work myself?

At least, the service manager also indicated the repairs alone will exceed the value of the Mercedes. Basically, this mercedes is a money pit. Putting more money into mercedes is more than its worth.

I do have another Mercedes e320 wagon same year model that is fully functional but needs body paint and interior restoration.

Any other ideas out there now that I know where I stand on this situation? Anyone out there need parts or suggestions as to what for me to do as advise? Thanks to all for reading.

If the car is clean and you like it, get a second opinion from a welder/fabricator. Just because the part is no longer available does not mean it cannot be cut from a parts car. A welder fabricator may not even need a new tunnel but can make a repair panel instead.

__________________
"Rudeness is a weak man's imitation of strength" - Eric Hoffer

Your insurance may cover it. I'd think you could get a panel from the junkyard too.

__________________
[SIGPIC] Diesel loving autocrossing grandpa Architect. 08 Dodge 3/4 ton with Cummins & six speed; I have had about 35 benzes. I have a 39 Studebaker Coupe Express pickup in which I have had installed a 617 turbo and a five speed manual.[SIGPIC]

..I also have a 427 Cobra replica with an aluminum chassis.

dmorgan, I recommend having a body shop evaluate the damage and give you an estimate to repair the transmission tunnel. Realize that most likely the seats and carpet need to be removed to avoid damage during the repair, possibly some wiring too. A thorough undercoating of the repaired area will be necessary to ensure the newly welded areas do not rust … and that is easier said, than done properly. Think the repair through before throwing good money after bad. Anything is possible, given enough time and money; however, it may not be cost-effective to repair your beloved 1994 E320 wagon as other costly repairs may soon follow.

__________________
Fred Hoelzle

Sugar Bear, t walgamuth and Ferdman, thanks for your latest posts. Much appreciated.



I had the Mercedes towed back to my home again without any repairs at this time. Still exploring my options as to what to do next.

I spent some time on searching the transmission tunnel replacement part. Quite a few websites have the transmission tunnel available for sale. The problem is the transmission tunnel part is not available in real time for sale and, only to find out some of the websites don't have the transmission tunnel part. Why the websites advertise transmission tunnel for sale when it is not there and/or discontinued? These mercedes parts websites needs to be updated on parts availability or not. Some websites have ridiculously high shipping charges that cost more than the actual transmission tunnel part price.

Anyway, I submitted a wanted part on this forum to see if I can get any response. I am going to leave it at that for now.


I just need to explore and pursue choices/options are available that is right for me. Thanks to all for reading.