hey all, i was hoping someone could post the definitive list of all the parts needed to be pulled from a Manual 240D for a complete 300D auto to manual swap. i've been reading up all over the forum but a lot of the talk is early experimental stuff, nothing really set in concrete in list form (yes, i've read R Leo's VERY helpful post. it's great for the work and the issues that might come up, but not for a "shopping" list.) i'll start:

manual trans.....

__________________
1985 300D - 1984 Euro 280E AMG Clone (SOLD) - 1978 280CE (SOLD) - 1983 300D (SOLD) - 1981 300D (SOLD)

I have pressure plate, flywheel and friction disco for sale. PM

__________________
http://superturbodiesel.com/images/sig.04.10.jpg
1995 E420 Schwarz
1995 E300 Weiss
#1987 300D Sturmmachine
#1991 300D Nearly Perfect
#1994 E320 Cabriolet
#1995 E320 Touring
#1985 300D Sedan
OBK #42

that's cool, i'll keep it in mind. but what i really need right now is a complete list of parts as i have two sources for complete systems right now and need a checklist before the money is spent. gotta do this right as i'm learning as i go. i know a bunch of you have done this swap. thanks for the help!

__________________
1985 300D - 1984 Euro 280E AMG Clone (SOLD) - 1978 280CE (SOLD) - 1983 300D (SOLD) - 1981 300D (SOLD)

Trans, linkage (youll need to make your own), ds (chopped), shifter, pedal assembly, clutch, flywheel, bolts for both of those, 240d auto trans cross piece, heavy duty trans mount.

__________________
http://superturbodiesel.com/images/sig.04.10.jpg
1995 E420 Schwarz
1995 E300 Weiss
#1987 300D Sturmmachine
#1991 300D Nearly Perfect
#1994 E320 Cabriolet
#1995 E320 Touring
#1985 300D Sedan
OBK #42

...pressure plate, master and slave cylinders, hydraulic line for clutch, machinist to match balance flywheel, new idler bearing and throw out bearing, Chevy S-10 clutch alignment tool.


You don't need to make your own linkages, just shorten the 240D linkages and re-thread them.

__________________
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

heres my list
inside the car
shifter with 4 bolts and wire harness all the way to the plug on the driver side inside tunnel wall under the carpet
pedal assembly, keep the parts car brake pedal clip, pull the entire harness for the clutch pedal switch
hydraulic hard line from the clutch master through the floor
hard line clip and screw
under the car
3 shift rods, if they are 240D rods shorten approximately 4 inches and run a die to extend the threads. sears has the dies and they work awesome.
6 shift rod clips
240D auto crossmember
240D exhaust hanger
240D auto speedo cable
keep all of the trans bell bolts from the parts car
keep the flywheel bolts from the parts car, manual bolts are shorter than auto bolts
240D manual flywheel, or 300D but not necissary
clutch pressure plate if it is good, otherwise buy a new one, but get the pressure plate bolts either way
use 300D rubber trans mount type without the extra strap
under the hood
rubber line from brake reservior to clutch master

to complete the install you will need to shorten the 240D driveshaft, take the opportunity to replace the rubber doughnuts as well

__________________

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)

You don't necessarily need to swap speedometer cables. I kept mine in my 300D.

__________________
DJ


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

on mine the extra length caused it to bind, but I guess if routed differently it could work.

__________________

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)