I think I have an idea to make the flywheel I got work, it’s odd that all the used flywheels I find (almost all w201) don’t have any timing Windows.
My plan is to pick up a w124 flex plate, line up all the crank bolt holes and bolt them together, mark the flywheel, measure the distance between the teeth of the flex plate and the top of the windows, and cut the windows off the donorflex plate and weld them on to the flywheel since is doesn’t have any windows on it currently.
On BMWs if this era they had similar spots on the flywheel, they were just smaller, I had one come off on a gray market e21, I was able to find where it went, drill and tap the hole and with red locktite put a bolt in its place all while the whole car was still together and it ran perfect after.

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1989 Mercedes 260e
1972 GMC shorty van
1982 Harley Davidson Ironhead

Just wanted to update this

So I had great success with the swap, I can confirm that the front 190E driveshaft slid in to the rear 260e shaft and was the perfect length.

I ended up buying a new flywheel from Mercedes, but I ordered the 9.5” accidentally, I would recommend anyone else doing this swap to get the 9” or 8.5”, as LUK Sachs and others make clutch kits for them, I was stuck since one made a clutch kit for the 9.5 anymore so I had to get it from the dealer as well($550)

For the shift rods I cut them on the flattest spot, threaded the rods, and got threaded sleeves and lock nuts, then I was able to get them to the correct length and take them to a buddy to have them welded, with the bushing side still adjustable for fine tuning




Getting the exhaust out was a pain, I had to remove the manifolds from the down pipe, the down pipe section from the rear mufflers, and remove the large 22mm bolt that goes to the steering right under the manifolds

Mercedes and BMW use the same size exhaust studs, so I was able to get nice copper nuts with a shoulder from my local import parts store(VW uses the same size, but don’t have the shoulder so it’s a good upgrade for them so it’s was a common part in stock)

I was able to get new flywheels bolts from the dealer next day for decently cheap, finding the torque spec on anything was kinda a pain, but I was able to find this

The final drive ratio from my auto to the early 190E manual transmission was surprisingly really nice together, the last manual swap I did in a BMW e34 was not such. High way driving is very pleasant and from a stop it moves a lot faster then the auto

Wiring the neutral safety switch was easy, finding the plug that would fit in the reverse light switch on the shifter wasn’t, I ended up just using just the pins from another female connector(the seat adjustment pigtail) and removed the housing but after that very little wire had to be added


Plumbing the clutch was really easy, all the 190E bent lines fit in the groves under the carpet nicely

Early 190E pedals(and possibly all) had a different brake light switch that takes a different connector and it was so bad on the donor parts that it had to be replaced but w124 wouldn’t fit, I ended up using a BMW e28 as it’s a simple 2 spade connector and same diameter as the holding hole.

For a shift boot I hoped the w201 would fit but it didn’t, unable time find a w124 boot I searched the junk yard with the center section of a wrecked w124, I found a boot off a roughly 2002 Subaru Outback, it was pretty damn near the correct size, I stretched it over the auto shifter trim ring, added some rivets and it worked great, and new ones are plentiful


The transmission crossmember is cheap and I got it here off pelican parts, I wouldn’t waste your time trying to build one when a Mercedes one can be had for $35.
This part bolts up a lot closer to the front of the car then the auto one, two bolt holes line but, the other two are there, but have been filled with plastic plugs, remove these and you’ll see a threaded holes under and the crossmemeber bolts up perfectly

The flex discs from a 190e to a w124 are different, so when I ordered 2 new ones for the w124 I couldn’t use one, so I am running a 190e disc transmission side and a w124 diff side

The w124 Speedo cable reaches just fine and works perfect with the manual

If you are unable to find a curtain 2 gears, your linkage is either to short or too long, there is a grove in the bottom of the shifter assembly as well as holes in the arms coming down, you can push an Allen though all these and the shifter is in neutral, put the trans in neutral and the rods, if correct length, will slip on both sides, if not, adjust accordingly. I was surprised to find that neutral doesn’t have any side to side play like most cars, but with the rods adjusted right, the shifter feels great and tight

Pressure plate bolts I was unable to find new so I got them from a hardware store and those with combination some lock washers to keep them tight it worked great

You will need a pilot bearing, the autos don’t use them, and the kits didn’t come with them, funny enough that was east to get because it’s the same part number for a VW so a FAG bearing was cheap and easy to find

There is a nipple off the brake master cylinder that is just capped off on auto cars, cut this and get the cloth braided rubber line to run it to the clutch master, also it is the same size for BMW and other German cars so finding this hose by the foot was easy and cheap so don’t cut pennies here

Apparently Sachs owns FTE, so when I bought a nice Sachs master, I was a little taken back when the part in the unopened box was a FTE, so if you see both options, go for the cheaper as the seem to be the same, your just paying for a box

Ordering parts from Mercedes with out a vin can be done online from places like MBpartslive and others, the emailed me after the order asking for a vin, I told them that it was for a swap and didn’t have a proper vin, they where fine with that answer

I have list of all the part numbers for everything I used Incase anyone needs them or if you have any questions about this swap I would be more then happy to help.

Sorry for any spelling errors in all this, I’m half asleep and just thought I would share things I found


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1989 Mercedes 260e
1972 GMC shorty van
1982 Harley Davidson Ironhead

Nice work.

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CENSORED due to not family friendly words

Congrats!!!


Two things:

The correct harness plug for the reverse light switch can be found on the air temp sensor in the domelight. Grab one from the JY when you get a chance if you're so inclined.

The Sachs kit for the 9.5" clutch can be found for about $300 if you're persistent, but none in US, will have to be sourced from Europe.

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Watch him go!!! link

#dontdealwithkahlil

Thanks I’ll be heading to the yard here soon!

And damn I wish I would have known, I found the Sachs number but couldn’t source it online


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1989 Mercedes 260e
1972 GMC shorty van
1982 Harley Davidson Ironhead

nicely done!

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Hanno
'79 6.9 Sold (after 27 years)
'83 280SL, 5 spd.
'94 E320 Sdn. 5 spd conversion
'02 E320 Sdn.(on loan to mom!)
'87 300E (5 spd. conversion) Sold
'05 E500 Wagon

I’m looking for the 9.5 clutch kit do you have any links ?

I got my 9.5" clutch kit here: https://onlinecarparts.co.uk/

Lots of back and forth to confirm correct kit.

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Hanno
'79 6.9 Sold (after 27 years)
'83 280SL, 5 spd.
'94 E320 Sdn. 5 spd conversion
'02 E320 Sdn.(on loan to mom!)
'87 300E (5 spd. conversion) Sold
'05 E500 Wagon

How much did you pay ? And thanks for the link