finally finished today. I am now under manual 4spd power. !st reaction is, its still no road racer but it is more up to a small gasser type performance. It is definitely more fun to drive than an auto. I did not get any added vibes all the way up to 80 which is all i can do here without going on the highway. I did notice a vibe when accellerating through a hard turn. I may have to look for a clearance issue on the crossmember. I plan to get a different one soon so I will check it then.

some observations for the next guy.

1. do a parts inventory and get everything you need before you start, if its a small inexpensive part get two. I was stopped for: flywheel bolts, pressure plate bolts, shifter linkage clips
2. the hydraulic line on the trans is no longer available. I took mine to the local hydraulic line maker and got an exact copy for $30. thats half what MB wanted if they had it
3. make sure you mark the flywheel before you remove it and make sure you get your flywheel balance checked. mine was not nuetral it was out by 17 grams.
4. get an auto 240d cross member so you dont have to make one. I made mine but I will get the 240D auto one soon and replace it
5. shift linkage is cut by 4 inches. If I did another i would cut the short one 3 3/4 because it needed a little more length. AT 4" cut it was still ok for mine but less engagement than the other two
6. sears has a $17 dollar set of 6 metric dies. I was skeptical of the quality so I bought 2 sets. these are actually pretty good quality. I ran the 10mmx1.5 die on the shift link for the additional 4 inches on all three with one die and it cut like a champ. Use plenty of oil, I had trans fluid next to me so I used that.
7. the driveshaft is spun weld construction so the driveshaft guys didnt like working on it.
8. the clips on the trans link are a bear to install. I found that if I jam the end of a sharp probe tool into the fold in the inside it opens the clip snap. the probe is about 8 inches long and easily reached up in between the trans and tunnel. then they slip right on the shift rod and then I could I pull the sharp probe out of the side locking it in place. without the tool, 45 mins of cursing. with the tool, about 1 minute each and success.
9. get all of the harnesses from the donor. follow the auto harness inside and to the upper driverside firewall and unplug. the new reverse switch harness plugs right in, no muss, no fuss
10. 240d manual speedo cable works with no alteration.

I will edit in more as I think of them.

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1982 300CD Turbo (Otis, "ups & downs") parts for sale
2003 TJ with Hemi (to go anywhere, quickly) sold
2001 Excursion Powerstroke (to go dependably)
1970 Mustang 428SCJ (to go fast)
1962 Corvette LS1 (to go in style)
2001 Schwinn Grape Krate 10spd (if all else fails)