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#1
11-19-2013, 09:12 AM
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In case anyone missed it... the easy way to get a W201 5-speed to mate to your OM61X
A guy over on STD posted a thread about how he retrofitted a W201 five-speed (where the starter hump is on the left) to his OM617 300SD. It looks quite simple, so I thought I'd post it here for those who might be interested.
Also, I'd be curious as to what everyone thinks of it, as I'm pondering doing this to my 'SD at some point.
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"Senior Luna, your sense of humor is still loco... but we love it, anyway." -rickymay ____ "Your sense of humor is still loco...  " -MBeige ____ "Señor Luna, your sense of humor is quite järjetön" -Delibes1982 300SD -- 211k, Texas car, tranny issues ____ 1979 240D 4-speed 234k -- turbo and tuned IP, third world taxi hot rod 2 Samuel 12:13: "David said to Nathan, “I have sinned against the Lord.” And Nathan said to David, “The Lord also has put away your sin; you shall not die." 
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#2
11-19-2013, 09:43 AM
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The angle grinder cutouts work, but could easily be done with a horizontal mill or a hole saw & steady hand, if you wanted a more polished looking bellhousing. Then weld half tubes or angle iron in the cutout areas.
It's a beautifully simple and well done conversion in my mind. Yes the cutout on that transmission are a little large, but it's a prototype and really, your average 617 isn't going to put down enough torque to crack a bellhousing.
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$60 OM617 Blank Exhaust Flanges $110 OM606 Blank Exhaust Flanges No merc at the moment
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#3
11-19-2013, 12:11 PM
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I second the welding of something to bridge the gaps created by the cutouts to both restore the strength and to keep dirt / junk out.
I would do this conversion instead of a 240D 4-speed swap myself.
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You can't always get what you want, but if you try sometime you just might find you get what you need.
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#4
11-22-2013, 10:50 AM
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I read that thread back when it was new, this is definitely thinking outside the box.
Using the 5-spd from a W124 or W201, it has a 23 Spline input shaft compared to the W123 4-spd with the 10 Spline Shaft. The Snout that fits into the Pilot Bearing is shorter that the 4-spd. The guy in that thread said he used a Double bearing what ever that is, but didn`t list which bearing or a number for it. I suppose a Bushing could be made out of Oilite Bronze, and made a little longer to make for the difference in length. In this picture he is using an adaptor plate, so that will move the Input shaft back further too. Which Clutch Disk would work with the OM616 or OM617 Fly-Wheel? 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
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