Folks,

I have a 1978 240D with an automatic transmission. I want to change over to a manual transmission. I have located a w115 240D (VIN 115.117.10.018970) with a manual transmission in a junkyard. Will the transmission, flywheel, neutral safety switch, and linkages match up? Will the manual transmission driveshaft be the right length to work in a w123 240D? Any insight here is appreciated.

Thanks,
Andrew

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'Betsy the Getaway Car' : 1978 MB 240D, 582k
'The Mistress of the Sea' : 2001 Giant Boulder, 10.30k

I know someone who did it and I think everything worked out good except for the shifter linkages, he had to slightly modify them.

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1985 300TD Turbo Euro-wagon
1979 280CE 225,200 miles
1985 300D Turbo 264,000 miles
1976 240D 190,000 miles
1979 300TD 220,000

GONE but not forgotten
1976 300D 195,300 miles
1983 300D Turbo 175,000 miles

http://i42.photobucket.com/albums/e3...e485-1-2-1.jpg

79, thanks for the quick response. Do you recall what kind of modifications the linkages required? I imagine it would be the sort of thing you can do without a torch or welder?

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'Betsy the Getaway Car' : 1978 MB 240D, 582k
'The Mistress of the Sea' : 2001 Giant Boulder, 10.30k

Sorry I don't remember exactly what he had to do, I think one of the rods had to be shorter.

__________________
1985 300TD Turbo Euro-wagon
1979 280CE 225,200 miles
1985 300D Turbo 264,000 miles
1976 240D 190,000 miles
1979 300TD 220,000

GONE but not forgotten
1976 300D 195,300 miles
1983 300D Turbo 175,000 miles

http://i42.photobucket.com/albums/e3...e485-1-2-1.jpg

You won`t need the NSS. the manual trans doesn`t use it.

When I did my swap, I used a 82 240D 4 spd, and put it into a 85 300D. so the measurements I had and the one`s you will have are different. But the shift rods might be the same length since you are going 240 to 240 just different chassis models. the engines are probably the same length as well and the trans. so they might just connect w/o any cutting.

I cut 2 rods 4" and the third rod 3 1/2", then threaded the ends for the end piece to screw back on.

I connected the shift rods to the transmission levers. Make sure the 3 levers are in the neutral positions.
I made a note as to how much thread was on either end of the screw on piece with the bushing.
then removed the ends, and attached them to the shifter levers. then laid the shift rod on top of the end piece and marked with a black marker where the new threads will be, and where to cut off the end of the rod.

Did that to each rod, then cut off the ends, and threaded them.

I did have to tweek and bend each one so they would clear each other and the body.

under the shifter, where the 3 shift levers hang down, run a drill bit or nail through the holes to keep the levers ligned up. the levers each have a hole, and look close on either side of the levers is a piece that hangs down with a "V" cut in it, this will hold the nail in place so the levers don`t get out of position. this way you will be in the neutral position as far as the shifter goes.

Charlie

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there were three HP ratings on the OM616...

1) Not much power
2) Even less power
3) Not nearly enough power!! 240D w/auto

Anyone that thinks a 240D is slow drives too fast.

80 240D Naturally Exasperated, 4-Spd 388k DD 150mph spedo 3:58 Diff

We are advised to NOT judge ALL Muslims by the actions of a few lunatics, but we are encouraged to judge ALL gun owners by the actions of a few lunatics. Funny how that works

Charmalu,

Thanks for the step-by-step. I have the transmission manual for the post-1976 transmissions, but they assume I already have all of the exactly correct pieces.

Does anyone know about whether the manual driveshaft from a w115 chassis will fit a w123 with a manual transmission?

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'Betsy the Getaway Car' : 1978 MB 240D, 582k
'The Mistress of the Sea' : 2001 Giant Boulder, 10.30k

The clutch off the junkyard car still has 3mm of lining on each side. Is this enough material for the transmission to work properly?

The manual transmission manual says the clutch plate lining should originally be 3.6 to 3.8mm on each side. It also says that 2mm of wear is permissible. I take this to mean that the clutch plate should be replaced when it gets down to 1.6-1.8mm. Should I go ahead and replace the clutch or run it as is?

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'Betsy the Getaway Car' : 1978 MB 240D, 582k
'The Mistress of the Sea' : 2001 Giant Boulder, 10.30k

For the automatic's neutral-switch that you'll be eliminating, you will need to bypass/jumper the starter portion of your wiring harness/plug. And wire the manual-tranny's backup-light switch to the backup-light portion of your harness/plug.

Happy Motoring, Mark

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DrDKW

Remember, to measure twice and cut once on the shift rods. the measurements
I posted and the one`s you come up with might be different.

With the NSS harness. I removed the large piece of carpet on the drivers side that is next to the go faster peddle. you will see where some wires come through a large gormett, these are from the NSS.
there is a plug that is up by where your knee would be. this plug has 2 purple wires, these are for the starter.
I forget the other 2 colors, but they are for the back up lights.

pull the plug connection apart, and pull the wires out through the gromett from under the car.

I cleaned up the gromett to degrease it, and filled the hole with RTV and reinserted it.

The plug from the manual shifter is for the back uplights. plug this into the connection the NSS harness connected to.

The 2 purple wires I just connected them together in the plug. there were 2 pin connectors that had a wire soldered together between them. think it was out of the 240 donor car. or it might be in the pigtail from the shifter. I forget on that one.

The whole swap is pretty much plug and play.

Charlie

__________________
there were three HP ratings on the OM616...

1) Not much power
2) Even less power
3) Not nearly enough power!! 240D w/auto

Anyone that thinks a 240D is slow drives too fast.

80 240D Naturally Exasperated, 4-Spd 388k DD 150mph spedo 3:58 Diff

We are advised to NOT judge ALL Muslims by the actions of a few lunatics, but we are encouraged to judge ALL gun owners by the actions of a few lunatics. Funny how that works

And about the pedal assembly -will that swap over from the w115 into the w123?

The junkyard fellow tells me the pedal assembly from the w115 will not fit the w123. I grabbed the pedal assembly from another w123 on the lot.

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'Betsy the Getaway Car' : 1978 MB 240D, 582k
'The Mistress of the Sea' : 2001 Giant Boulder, 10.30k

yeah, they are totally different.

If you go to this thread, and down to post 32, I posted some comparison pics of the different pedal assemblies I had lying around. Good luck! you will love this change!

http://www.superturbodiesel.com/std/every-single-thing-need-convert-four-speed-t-851.html

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