thanks! can't wait to get it fully buttoned up, will have to be next weekend probably.
Heres a short walkaround, engine start video. It runs pretty well I think, I have not adjusted the valves yet or changed any fluids. Not really any major leaks either

http://www.youtube.com/watch?v=BKJAyxQbCKA

Heres a video of the first test drive with the 5-speed. I had an adjustment issue on the reverse/overdrive rod. you can see it pop out of gear and grind! Horrible to hear, especially with the floor missing. Thats been resolved now though, I had to have someone else come and shift while I was underneath to really identify the lack of travel issue. Hard to tell from one side, you need some help. For a 240 though, the car moves right along. Enormous improvement over the auto.

(wear headphones for the full effect of the grinding, it was a horrible noise) Taken care of now, thankfully. I was pretty unhappy for a moment

http://www.youtube.com/watch?v=MWEbgU9j1Rw

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Bumper and strip I think is fine. Not sure about the other parts. I'll shoot some pics in a few days when I can get to the car. Where in CNY are you. You can't be that far off from here in CT. Therezls 2 other W123 parts car there that belongs to my friend so I am sure you can get what you need between the 3 cars. But I have to ask him first.

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85 300D turbo pristine w 157k when purchased 161K now
83 300 D turbo 297K runs great. SOLD!
83 240D 4 spd manual- parted out then junked

ironically, the car is in CT, down near stamford. ive been driving down on weekends. Where in CT are you?

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Excellent! Are you gonna be there this coming weekend? Maybe we can hook up. Car is in Shelton in a pleasant wooded lot with no electricity.

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85 300D turbo pristine w 157k when purchased 161K now
83 300 D turbo 297K runs great. SOLD!
83 240D 4 spd manual- parted out then junked

yeah, Im coming back down friday, pm sent!

This week I have to think about the overdrive problem, which is not eliminated as I hoped. It won't stay in overdrive all the time, but works perfectly in every other gear. Pretty irritating as overdrive was the whole point of this complex swap! The most annoying part is that all the cross chassis risks I took matching 240 and 190 parts together have resulted in success, and the problem is now completely unrelated to the swap itself! Hopefully this weekend I can shed some light on it.

Ive found problems with the stick apparatus, and also with a second stick apparatus, but Im not sure if those issues have any bearing on whats happening here. Popping out of gear would have to be an internal transmission problem, which means I may have to take the back of the transmission apart. Fortunately, that can be done on the car, but it may have to come out if I find something further.

I am disassembling my 717.412 and comparing it to the reassembly pics of the 717.411 thats in the car. Hopefully its all in the stick.

I cannot believe how complex the stick apparatus is, more complex than the entire transmission! Parts may have to be ordered for that as well.

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Sounds like normal German over-engineering to me !

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83 SD

84 CD

Have you tried a different fluid? Synthetic maybe? I'll give you a call later.

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85 300D turbo pristine w 157k when purchased 161K now
83 300 D turbo 297K runs great. SOLD!
83 240D 4 spd manual- parted out then junked

I already have a Euro '84 300TD with a factory 5-speed and a decent '82 240D with a 4-speed manual, but I'm very interested in your 240D - W201 5-speed conversion.

Other than linkage/overdrive issues, is the W201 5-speed a direct bolt-up to the 240D 616 motor & clutch?
If the 240D already has a 4-speed manual, will the 5-speed need driveshaft modification?
Also, which W201 5-speed - 190E or D - did you use?
Or do those use the same tranny? Thanks.

Happy Motoring, Mark

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DrDKW

The short answer is that you will have to modify everything!

The way that I went was swapping the last three inches of the bell housing, swapping the ends of the transmission input shafts, modifying the drive shaft, linkage bars, and trans mount, and using a mix of W201 and W123 parts putting it back together. Add a number of machinist and welding steps into the process.

Modifying the bellhousings easily is all about the input shaft cover plate, what made this possible was that the plates match pattern and distance wise on SOME of the 5-speeds and SOME of the 4-speeds.

here are a couple threads that go into this in more detail, im still working on both of them, but one is the distilled version of the other and they are from different perspectives.

This is about the project in its entirety (as I struggle along in pursuit of this goal )-

http://www.superturbodiesel.com/std/617-franken-5-speed-t-323.html

And this is the how to do thread which is not complete, I have only gotten so far as putting the tranny back together-

http://www.superturbodiesel.com/std/how-adapt-w201-speed-om616-om617-applications-t-965.html

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well, Ive got definite physical problems with both my W201 shifters which may be contributing to this overdrive problem. Ive got three here, one is random and damaged, and the other two are correct, but are worn in different ways.
I took the back end of the .412 apart, and I dont think something is wrong with the detent on the transmission, I still think its a translation issue on shift throw.

meanwhile the car took one step back by dumping the contents of the entire fuel tank out onto the driveway while I was gone all week. That will have to be fixed before any more test drives. Both lines are rusted out, so ill do both at the same time.

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Well then, unless that elusive 5-speed 240D turns up at the Pick-N-Pull, mine will be staying a 4-speed for the forseeable future.

Happy Motoring, Mark

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DrDKW

Shifter is fixed, I combined the best parts of the two good ones, then used 12 dimes to replace the worn out rubber bushings! pic of that below. made a huge difference in shift feel, I love it. I will have to have some brass bushings made, but for now, the dimes get the job done nicely.

I have identified the problem with the transmission. I forgot several tiny crucial parts when I put the thing back together. took the whole thing apart, reassembled it, and realized I had spaced an important snap ring, so now I have to do the whole thing again. Around 5pm today I was extremely irritated and had to go for a walk before I did something destructive to the car.

Replaced both supply and return lines with rubber stuff from autozone, they were both actually broken right above the rear subframe.

next issue resolved today is that the oil cooler sprung a leak down by the hose attachments. that had to come out, O-rings had to be replaced, and some RTV grey for good measure put in.

Attached Thumbnails

   

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overdrive is in business!

http://www.youtube.com/watch?v=3vZEJbGeuSk

when I put it together, I forgot 3 little internal pieces all specifically related to the overdrive. very foolish mistake.

Now I can move on and get this suckers passenger side floor closed up and start putting miles on her

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ALMOST had it ready to take upstate this morning. Unfortunately missed my cutoff time, and had to step back and get ready to leave.

Im having some issues getting the driver seat to mount so im comfortable taking this thing around NYC commuter traffic yet, and I did not complete the hole repair.

Close though, I hope to be able to actually do my 330 mile test drive next weekend.

Contemplated leaving the hole undone and doing the test drive first, but man, it is LOUD underneath like that. Id probably be deaf in a matter of hours.

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Hey what happened? I left you a voicemail last Sunday around noon time but didn't hear back from you. I assume you do not need the parts anymore?

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85 300D turbo pristine w 157k when purchased 161K now
83 300 D turbo 297K runs great. SOLD!
83 240D 4 spd manual- parted out then junked