I drive an 85 300D turbo (California).

Ok, I have a 240 manual transmission and the needed parts for the swap available to me for little to no cost. I need everyone's input on whether or not I should go for it:

1) I understand that the 240 auto cross member eliminated much of everyone's vibration issues. However, how much is left? I don't want to be badgered by vibration.

2) Has anyone used the stock 300 naturally aspirated manual transmission flywheel with their 4 speed swap? Did you have vibration troubles?

3) Did anyone try the previously proposed modified (made heavier) 240 flywheel or the flywheel from a gasser W123?

4) I do regular towing of firewood, compost, and random things (1500-2250 lbs.), will the new transmission and clutch be up for this task?

I don't want to go through the trouble of this swap to be anything less than happy with my decision to do so. I need experienced individuals input.

Thank you for you help in advance

The 300D flywheel that everyone says to buy is the N/A one. The turbo diesel was never offered with a stick, so if someone says to buy a 300D flywheel they mean the non turbo one.

I've heard of people with late '84's and all '85's having issues as the main shaft is a different diameter or something along those lines.

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1981 300TD 4 speed manual
Euro bumpers, zender valance and skirts, H&R springs, billy HD's, leveled sls, real AMG Pentas 16x8 et11, vdo boost/egt gauges intergrated into ash tray, eurolights, led 3rd brake light

I have the exact same car as you. I installed a 4-spd from a 82 240D, and used the 240D FW. It can be used. but it weight 28lbs and the 300D 5 cyl FW weight 38lbs. the extra weight of the 617 FW is suppose to smooth out the 5 cyl eng.

1st gear, 2nd gear and 3rd gear are smooth, and as I remember (car has been down for over a yr. mainly because I procrastinate long story) I can run the speed in 3rd upto 50mph or better and shift into 4th. when the RPM`s drop down to around 2700 then I feel some roughness, probably because it is starting to lug some. shift into 3rd and all is good.

You will use the 240D auto X mount because it lines up to the next set of holes back, (not because of a vibration issue) the 4-spd is shorter than the auto trans, but then there is the added cylinder of the 617, and the way it lines up, the auto X-mount lines up perfect.

If you do some searching, the discussion of adding weight to the 240 FW has been beaten to death. bottom line, I wouldn`t do it.
There are some 617 FW`s floating around, just have to start searching, and or start hitting the PNP`s and other Junk Yards (JY) on a weekly basis, and sooner or later you will stumbled onto one.

A gasser FW might be lighter and the FW might be drilled different for the gasser Crank. Don`t know for sure. they would be rare too.

The Clutch will probably hold up fine what ever you throw at it.

The 85 300D Crank doesn`t have the standard 35mm hole like all the previous years for the pilot bearing. for some reason for the 85 they gave it a 34mm hole.
this issue is discussed in some of the below threads.

Did you read this?
http://www.peachparts.com/shopforum/diesel-discussion/334272-300d-4-speed-swap-you-happy.html

http://www.peachparts.com/shopforum/diesel-discussion/319105-question-flywheel-balance-i-screwed-up.html

http://www.peachparts.com/shopforum/diesel-discussion/294398-240d-automatic-transmission-swap-manual.html#post2664858


http://www.peachparts.com/shopforum/diesel-discussion/273316-300cd-manual-conversion.html

Every single thing you need to convert to a four-speed

http://www.peachparts.com/shopforum/diesel-discussion/333235-need-help-nss-going-auto-manual-trans.html

http://www.peachparts.com/shopforum/diesel-discussion/333784-neutral-safety-switch-troubleshooting-84-300d.html

http://www.peachparts.com/shopforum/2308136-post2.html

these guys might be a source for a pilot bearing?
Pilot Bearings | StreetPerformance.com


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

Charlie - Thanks for your insightful response! Nothing like someone who has actually done a job to give you good info. I'm guessing this would be WAY cheaper than using an adaptor system and an American trans.

Any idea on how much power the 240 trans can handle? I'm hoping to eventually get 300ish HP out of my race OM617 and I don't want to be scattering transmissions. The S-10 won't be too heavy (I can't see more than 3K lbs) and in LSR we don't do drag strip launches so no extreme loading of the trans/clutch at the starting line.

Thanks again
Dan

Dan I don`t know how much HP these transmissions can handle. the 240 is 67hp, and the 617 na is 88. the 617 turbo is 123hp. I think this same trans is used in the 280SE gasser in Europe.

These MB transmissions have the 3 shift rods that connect to the side of the box from the shifter. you can`t exactly speed shift them.

The 4-spds are 1:1 and once in a while a 5-spd manual will show up, but they were only sold in Europe, and 5th is OD. the only way to find one over here is from a Grey Mkt car, as well as the heavier 617 FW.

I found a 617 fw after looking for 3 yrs or so, at PNP in Carson City, Nv. yr ago last Nov, with some snow around and a cold wind blowing. but when I discovered what treasure I found, didn`t think about the cold.

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

Did you ever get that 300D flywheel in? What did that do to the vibrations?

I am familiar with the 34mm hole as opposed to the 35 mm hole in the crank, the difference in weight between the flywheels (and the mostly unavailableness of the 300’s flywheel), and the auto 240’s cross member. I have been searching this great forum for a while now to gain info on the swap before I get into it. Overall it seems simple enough although to complete but lengthy (to do it well). I find the vibration unappealing. Some said that their vibrations were substantially reduced after they installed the auto 240’s cossmember opposed to the modded auto 300’s. I hoped that in the years since those postings, there has been more progress on the issue or that someone had started with a 240 flywheel and made the switch to the 300’s. That person could say if that eliminated the vibrations. I don’t want vibrations but I also don’t want to spend money on an expensive flywheel that only slightly or doesn’t at all help the vibrations.

I didn't know the five speed was with overdrive. I just thought it had more gears for better driving. Nice to know. But, now I want the five speed and the associated flywheel even more.

When you pulled the flywheel there was no transmission there too?

The car I got the FW from was a 81 300D none turbo 4-spd. as I remember the trans was rough when I turned the shaft and shifted through ea gear.

I may have taken the Drive Line and shift rods, don`t remember now, just remember how excited I was. I hugged it and kissed it and slept with it under my pillow for a month.
I still go out to the barn and hug it now and then.

No the fw isn`t installed yet, the car has been on hold and covered with a tarp all winter with the eng out. I need to get motivated and get her put together.
But another problem/project is putting this further behind. the old Datsun PU has developed a noise, not sure what, but think a bearing in the trans is on the way out. so have to pull the eng and trans out of it. this is my DD and PNP go getter vehicle, so can`t have it down for too long. and the 240 is the only thing running.

The 5-spds are OD except for the very rare 86/87 W201 190E 16V 2.3 Costhworth eng 5-spd. this one has the Dog Leg 1st gear and close ratio with 1:1 5th gear. won`t work in our cars as the starter is on the wrong side as are the 5-spds for the W124 and W201.
The 5-spd you need is the one for our old Diesels with the starter on the right side. think some of the Euro w126 280E had them and some W123 gassers, but would be a Grey Mkt one.

This thread is a teaser for you, shows you what a 5-spd looks like and what you need to look for.
http://www.peachparts.com/shopforum/mercedes-used-parts-sale-wanted/334883-wts-717-400-5-speed-form-euro-300d.html

Here is one discussing the 617 fw and balancing it.
http://www.peachparts.com/shopforum/diesel-discussion/251365-got-my-300d-manual-flywheel.html

Have you read through this old thread by R. Leo? in this thread there is a picture of trying to modify the 240D manual trans X-mount, before the 240D auto X-mount was discovered to use.
http://www.peachparts.com/shopforum/diesel-discussion/88699-auto-manual-transmission-conversion-has-begun.html

Picture showing the difference between a 240 manual and auto X-Mount.
another interesting thread to read, click on the top right in the post.
http://www.peachparts.com/shopforum/2526160-post34.html

This thread shows why you don`t want to use the 300D X-Mount. will work for a while, but looks weak only using 2 holes where the 240 auto mount uses a 4 holes.
mercedes 240d 617 +4spd conversion

Don`t know if I posted this one.
Every single thing you need to convert to a four-speed


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

Dan, since your 617 is going into a S10 are you running the MB transmission as of now? If your looking for a stronger smoother shifting manual transmission I suggest leaving the MB world. I drive an MB stick daily and as Charlie said there are no quick shifts. This company has makes adapter plates to go from the 617 to a GM transmission. Might be the best thing for your S10.

OM617 to GM Manual Transmission | 4×4 Labs

They also make a kit to go to a Toyota W series transmission. I've been eying this for a long time.

OM617 to Toyota 5 speed | 4×4 Labs



To get back on topic. If you like driving a manual transmission. And like driving the MB, you'll love it when the MB is a manual!

A few of us have done this conversion and after I did it, I was totally happy with it. Charlie is a great guy and very knowledgeable on this topic. I picked his brain a few times during my build! GOOD LUCK!

__________________

Your much nicer to your 300d flywheel then I am to mine. Mine is slowly turning to dust as it comes into contact with my clutch I destroy mine a little bit every day.

__________________

Can you provide insight on the flywheel and vibrations?
Does he flywheel reduce vibrations?
Do you experience low RPM 4th gear vibrations?

Those posts are great I have read them all.

"Every single thing you need to convert to a four-speed"
Was new and awesome.

Thanks

I asked the exact same question two months ago and just finished the installation last week. I am absolutely ecstatic with the results and really, really, really like the car with the 4-speed manual. I have no vibration at all unless you really lug it, and you need to know what you're looking at to know that it didn't come from the factory this way.

I documented the installation here:

http://www.peachparts.com/shopforum/diesel-discussion/334272-300d-4-speed-swap-you-happy.html

Including the dimensions of the pilot bearing you'll need to make...

In the end it really wan't a huge deal and I just worked on it when I had time, just enough to keep the project moving. Everything "almost" just bolts up.

Like Charlie said, it'll take a long time for this silly grin to get off my face.

Happy to help in any way.

-Dan

__________________
1976 w115 300D 4-speed conversion!!
1985 w123 300TD 4-speed conversion!!

Non-Mercedes old stuff:
1941 Buick Special (Straight 8!)
1946 Luscombe 8a
1947 Willys CJ2a
1950 Chevrolet 4400 dump truck
1954 Chevrolet 3600 3/4 ton
1954 Cessna 195B
1955 John Deere model 40
1991 Ford Taurus SHO
2013 Jetta SportWagen TDI 6-speed (I sold out...

OK, I consider the project back on. I would still like to hear someone speak about if they noticed less vibrations with the 300D flywheel.

Yes. The 617 motor is a hopper at idle and with an automatic it hops so much you would think it has something seriously wrong with it. With the proper 38# flywheel it is so smooth you'll think its a straight six.

__________________
[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.