...continued...
 

Assemble the locking lever and spring mechanism...


http://www.peachparts.com/shopforum/...1&d=1380389272

...and fit it to the casing. This locking lever is the cause of the hardest part of the assembly. You need to make sure that that spring does ping itself off as you fit the main shaft and the 1st gear / 2nd gear shifting mechanism goes into place.


http://www.peachparts.com/shopforum/...1&d=1380389300


To get the main shaft in place you need about four hands – slightly lift the lay shaft and tilt it so you can get the 3rd / 4th gear synchro mechanism in position – whilst you hold the casing still so that you can push back the spring (with out pinging it off) on the locking lever. Pushing the 3rd / 4th shift lever downwards helps to get the synchro under the cogs on the lay shaft.

http://www.peachparts.com/shopforum/...1&d=1380390474

You can now fit the external shift lever on the 1st / 2nd gear shift mechanism as well as the pivot pin on the other side of the casing.

http://www.peachparts.com/shopforum/...1&d=1380390715

In an attempt to try and stop leaks I'm spraying the gaskets with Hylomar. This stuff essentially turns your gaskets into sticky fly paper. The stickiness is meant to stay sticky.


http://www.peachparts.com/shopforum/...1&d=1380389339

Assemble the 5th gear / reverse linkage in the intermediate plate.


http://www.peachparts.com/shopforum/...1&d=1380389386


http://www.peachparts.com/shopforum/...1&d=1380389454

...continued...
 

The peg on the end of the reverse lever has to be slotted into the cog on the sliding shaft that you fitted next to the lay shaft.


The fork end of the lock lever needs to be positioned correctly on the sliding mechanism part of the reverse / 5th gear linkage.


http://www.peachparts.com/shopforum/...1&d=1380389705


Once the intermediate plate is in place...


http://www.peachparts.com/shopforum/...1&d=1380389718


...you can fit the fifth gear assembly.


http://www.peachparts.com/shopforum/...1&d=1380389739

http://www.peachparts.com/shopforum/...1&d=1380389747

http://www.peachparts.com/shopforum/...1&d=1380389756

http://www.peachparts.com/shopforum/...1&d=1380390020


Then fit the speedometer gear


http://www.peachparts.com/shopforum/...1&d=1380390027

...continued...
 

Fit the rear cover / tail cone section – pass the long bolts all the way through the tail cone section, the intermediate plate to the main casing and tighten carefully. Align the 5th gear shifting mechanism with help of a stick / ball end on an Allen key.


http://www.peachparts.com/shopforum/...1&d=1380390173


Fit the shim and then the yoke before fitting the new nut.


http://www.peachparts.com/shopforum/...1&d=1380390260

Fill the gearbox with 1.5 litres of ATF.


http://www.peachparts.com/shopforum/...1&d=1380390187

If you are filling on the side – don't forget about the vent in the tail cone section!!!


http://www.peachparts.com/shopforum/...1&d=1380390201

I think that's it folks. I haven't shown absolutely every step - if anyone is unsure about it all let me know I'll try and answer your questions.

Casing dimensions
 

Information for modifiers

Over all length of the 717.412 from the end of the tongue that sticks out from the back of the gear box to the mating surface at the bell housing is 51cm

http://www.peachparts.com/shopforum/...1&d=1385108545

The distance in from the end of the tongue (for the mount) to the surface of the output shaft on to which you mount a flex disc is 4cm

So distance from bell house mounting surface to flex disc mounting surface is 47cm

(Small print - I've done my best with these measurements - they should be good within a few mm - use this information at your own peril!)

Thank you so much!!!

You're very welcome.

Have you thought about shifter rods yet?

I think that data and my (oh so clever) way of calculating the length you need might be necessary. What do you think?

There's an almost out of this world chance that this weekend the gearbox gets fitted and then your chance of data from me is gone.

Yeah, that would also be useful. If you can still do that, I would love it. Thanks very much for your help!

I still haven't fitted them if you need shifter rod dimensions and lengths...

Part number for reseal kit problems
 

I was asked by someone here about the ELRING reseal kit I bought. It seems that I bought one of the last ones out there...

Alternative numbers can be found here =>

MERCEDES 124 260 00 68 (1242600068) Gasket Set, manual transmission

Mercedes p/n = 124 260 00 68
Elring p/n = 597.899
Trucktec = 02.43.131 (never heard of them before!)

124 260 9201

Is the good Mercedes number. List is $94.

I believe 0068 superseeds to that number.

Nice one if you follow the trucktec part number on findpart.org you end up with that one too

MERCEDES 124 260 9201 (1242609201) Gasket Set, manual transmission

Complicated process this part number hunting...

...three times the price for the dealer part though - I'm glad I got that elring kit => doesn't help you though.

Making your own gaskets could be a possibility - though special attention should be made to their thicknesses - as the wrong thickness will mess up the clearances for the shafts (but these of course can be adjusted with the expensive shims from the dealer! <= vicious circle)

When I rebuilt an iron case 230G transmission I made my own gaskets, it seems to be leak free a year later.

I can get ~30% off list, when I redo my 200TD trans I may just have to pony up for the OEM gasket set. I need to buy the synchros before the price goes up on them too.

Awesome work. Excellent DIY.

Help for fitting the shifter linkages
 

Just in case you get to fit your refurbished gearbox and you don't end up using it as a bit of modern art...

...the connections at the gearbox are

http://www.peachparts.com/shopforum/...-side-view.jpg

Haynes says the connections at the shifter are

http://www.peachparts.com/shopforum/...-positions.jpg

I have a different shifter that has reverse back and to the left and the 5th gear is top and to the right

http://www.peachparts.com/shopforum/...d-shifter2.jpg

If you have one like this the connections shown in Haynes won't work - these do though

http://www.peachparts.com/shopforum/...ns-car-now.jpg