New clutch in My '83 240D - PeachParts Mercedes-Benz Forum

biobenz240d · #1 09-10-2006, 10:26 AM

I just replaced the clutch and all related components in my 240D. The job went amazingly smooth and took about 3 hrs to remove and 2.5 hrs to install. The release bearing was making noise and with 258k I felt it was time for a total replacement. I ordered my clutch from clutch express for 259$ and no shipping charge. The kit did not contain the pilot bearing but I was able to locate one locally for 15$. I put the car up on ramps for the front and jack stands for the back. ( a plus to have the car sit level for installing the trans and removing rear driveshaft) Remove the drive shaft and slide back, to gain room around the trans.(support rear of driveshaft on jack stand) Remove speedo cable and place out of the way. Remove shift linkage and zip tie out of the way .Remove bolt holding slave line and slave cylinder and tie up out of the way, don't disconnect the cylinder ( no need to bleed system later). Remove allen head bolts for starter ( don't remove starter , top bolts can be removed from engine compartment ) remove all but one top bolt and one bottom bolt, then place floor jack under trans. Remove trans cross member, pry bell housing apart to separate, slide trans back and lower out of the way ( trans weighs about 40 lbs) My release bearing was coming apart in pieces when I pulled the trans back. Remove pressure plate and disc( be careful not to rotate engine backwards when loosening bolts, 6mm allen head). Use a pilot bearing removal tool available to rent at Autozone. If needed ,remove fly wheel and have it resurfaced ( mine was in fantastic shape with only small lines from the disc , no blueing from over heating) I used 400 emery cloth to scuff up the flywheel then washed everything down with brake cleaner. Use never seez on the pilot bearing and tap into place using the old bearing to drive in the new bearing. Bolt up new disc and pressure plate, inserting the alignment tool (came with the kit). I used green Loctite and torque to specs. Clean out the bellhousing, , pull off the release arm and grease the ball stud. Replace release arm ,grease shaft that the release bearing slides on and lightly grease splines. Put on new release bearing and your ready to install trans . I put the trans up with the floor jack, got it started into the disc and wiggled it home. Reassemble in reverse order. when you think your all done recheck all that was removed to make sure you didn't forget anything . I started the car and put the trans through the gears to make sure all was good before taking the car off the jacks and ramps and road testing (ran smooth as butter) Caution is needed when working under a car supprted on jackstands and ramps. Use wheel chocks and two sets of jackstands , if available. All lot of this safety stuff is common sense but sometimes common sense is not too common.Good luck ,its alot easier than you think

,by the way my clutch disc only showed minimal wear as compared to the new disc ,I would bet that the orginal clutch would have been good for another 100k if it wasn't for the release bearing

#2 09-10-2006, 01:53 PM

Quote:

Originally Posted by biobenz240d

by the way my clutch disc only showed minimal wear as compared to the new disc ,I would bet that the orginal clutch would have been good for another 100k if it wasn't for the release bearing

For some reason, these have the highest clutch life of any car model I've ever seen. I've heard numbers on these anywhere from 250K-480K miles.

Our big trucks at work don't even get 100K on a dual disc ceramic clutch.

t walgamuth · #3 09-10-2006, 09:00 PM

very high quality over designed parts. low power. folks driving who have some sense. ..equals superior life.

at 250k i did the clutch on a 240 that my 18 year old son was driving. it wasnt nearly worn out but one of the springs that allow the disc to twist on the shaft popped and fell down causing it to drag. if i could have gotten it out we probably could have kept driving it if we had known that was all it was.

tom w