I completed the conversion of 300D turbo to a 4 speed manual today. It was not very difficult overall. I started it last week on 4/29 putting in a few hours here and there. I skipped working on it Sunday. It helped having a donor car for some of the smaller bits and pieces. This forum was also a lot of help.
I did use a 617 flywheel and I feel it made a difference. I drove it today after finishing it. It was a blast to drive. It feels like a whole different car than it was with the automatic. It accelerated smoothly, no vibrations or loss of RPM's when letting off the accelerator pedal as mentioned by others that had used the 616 flywheel.
Mercedes should really have built such a car!

__________________
DJ


84 300D Turbodiesel 190K with 4 speed manual sold in 03/2012

Sounds like a good save and post more details about your pitfalls or problems when you get a chance. Did you document in pix?

John in San Antonio

__________________
John Hughes, was in Landstuhl, Germany but currently in San Antonio, TX


1978 280CE Astral Silver now 59,xxx miles and counting "Silber-Kugel"
1986 300E Black Pearl Metallic 143,xxx miles 5-spd daily driver w/ blk leather "Schwarz-Schönheit"
1989 190E 2.6 (euro) 5-spd Desert Taupe 112,xxx kms Had to leave behind in Germany!!! "Helga"
1983 300D Pastel Beige now 312,xxx + miles SOLD

OBK#24

Where did you get the OM617 flywheel?

__________________
Jimmy L.
'05 Acura TL 6MT
2001 ML430 My Spare

Gone:
'95 E300 188K "Batmobile" Texas Unfriendly Black
'85 300TD 235K "The Wagon" Texas Friendly White
'80 240D 154K "China" Scar engine installed
'81 300TD 240K "Smash"
'80 240D 230K "The Squash"
'81 240D 293K"Scar" Rear ended harder than Elton John

300DT? I've never seen one of those, lots of 300D's though.

Congratulations on the conversion, enjoy the ride.

Nice. Glad to hear your done! Now enjoy!

__________________
1983 123.133 California
- GreaseCar Veg System

Congrats! Sounds like quite a ride.

How about a Youtube video?

__________________
1974 240D 3.0L 4(M) - 250K -OM617.910 + 300D FW + Rajay turbo power!
1977 6.9 3(A) - 84k

I'm looking forward to driving it. I know I'll have a chance to do that today.
I didn't take any photos which I kind of regret not doing. I just wanted to get it done. I figured there were better pictorials and write ups out there than I could do.
As far as pitfalls? I did spend some time bending the shift rods so they would not bind and I ended up modifying a transmission mount that came from an unknown Benz. The manual mount from the 240 would have needed too much modification and only had two mount points to attach to the frame. I lucked out getting a front driveshaft that was a perfect fit so modifying the 240 driveshaft could be considered a pitfall.
I changed my sig to show 300DT so members wouldn't just think it was a Euro 300D.
Youtube vid, anything is possible. I already have a video of the engine running outside of the car.

__________________
DJ


84 300D Turbodiesel 190K with 4 speed manual sold in 03/2012

Very very weak excuse!!! The keepers are not amused.......

__________________
Jimmy L.
'05 Acura TL 6MT
2001 ML430 My Spare

Gone:
'95 E300 188K "Batmobile" Texas Unfriendly Black
'85 300TD 235K "The Wagon" Texas Friendly White
'80 240D 154K "China" Scar engine installed
'81 300TD 240K "Smash"
'80 240D 230K "The Squash"
'81 240D 293K"Scar" Rear ended harder than Elton John

I would like to see how it drives compared to my 240D with the 617 swap sometime...

__________________
1979 240D- 316K miles - VGT Turbo, Intercooler, Stick Shift, Many Other Mods - Daily Driver

1982 300SD - 232K miles - Wife's Daily Driver

1986 560SL - Wife's red speed machine

Having one of each conversions with a 616 fw and the correct 617 fw, the difference is notable. Shifting with the correct fw is just so much better, and the idle is so smooth you'd swear its a six cylinder.

Too bad they're so hard to find.

__________________
[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.

One thing that is interesting is that the exhaust note sounds different even though I did nothing to the exhaust system. It could be that since there is less mass in the transmission tunnel and the sound resonates in the cabin. I like it. Sounds nice.
Sure thing Brian but I don't think mine will be as quick as your car because of the mods you've done to your engine. Plus you probably still have the 240's rear end.

__________________
DJ


84 300D Turbodiesel 190K with 4 speed manual sold in 03/2012

Sorry don't know how that could offend anyone?

__________________
DJ


84 300D Turbodiesel 190K with 4 speed manual sold in 03/2012

The "rogue T" is JimmyL's schtick; don't lose any sleep over it.

Thumbs up on your 4-speed conversion!

find a crossmember from a 240D auto, it will bolt right up. if you need one I have 2 spares, PM me. the linkage should work without bending, you will need to shorten it about 4 inches though

__________________

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)

I've already bent my linkages. They were binding for some reason after shortening them the required 4".
PM on the way.

__________________
DJ


84 300D Turbodiesel 190K with 4 speed manual sold in 03/2012