Five speed turbo swap, parts required...
 

Hello all!

First post here!

I am looking to do a manual transmission swap into my 1984 Mercedes 300TDT, I know, big surprise.

I have sourced a 5 speed transmission from an '82 240D and I would like to know if this transmission would bolt onto my wagon. Also, if the 5 speed deal falls through then I imagine a 4 speed would bolt up just fine as well?

Besides the advice on transmission/engine compatibility I am also looking for a list of parts I need to do the swap... I understand I'll need the big things like a pedal assembly and pressure plate but what about the trickier items? I have heard I need a crossmember from the 240D and a shortened driveshaft from a 300D.

Thank you very much for the help!

YES, that 5-speed will fit and it's crazy rare! The only sold them in Euro cars in the early eighties as an option, so finding them here in the states is extremely difficult.

As far as stuff you will need:

Tranny
Pedal cluster
Shifter
Slave Cylinder
All clutch fluid lines
Shifter linkages
Clutch master cylinder

The Navy items are 5-speed specific

You'll need a custom-length driveshaft. You could just take the 240D shaft and have it shortened. The reason you need to do this is that the 5-cylinder in your car pushes the tranny further back than the 4-cylinder in the 240D. This is the same reason that you may need a different transmission crossmember, although IDK what would work or if your 300TD automatic mount might even work. The 240D automatic crossmember works with the 4-speed in a 300D, as the 240D automatic and 300D manual transmissions end up being about the same length.

Ok good stuff man! It's only 300 dollars, I'll call the place up tomorrow and ask about shipping... CA to NY, could it get any worse? hahaha

Thanks!

It could be shipping from Europe. Some guys have bought them from there :).

Anyway, I edited my post after you replied to it to mention the driveshaft and crossmember too.

better make absolutely sure they are really selling you a 5 speed, and not a 4 speed that some parts guy simply assumes is a 5 speed because most manual tranny cars across all manufacturers are 5 speed.

this is a classic ooccurance that has happened many times.

... Iirc, the 5 speed wasn't out until 84...

You will need the shifter & rods, which will be hard to come by if you cant get it with the tranny. Make sure they aren't selling a five speed from a 190, that wont work. Also, as mentioned above, make sure they aren't counting reverse as "fifth" gear. I got a Euro 82 240D with a 5 spd a few years ago and swapped it into a manual 240D.

Is the shifter in a 4 speed any different from the shifter in a 5 speed? And those linkages will easily be the most difficult item to find since they are unique to the box. When I call up the folks with the box today I'll ask for the tranny part number and see if they have any other parts to go with it. Maybe the shifter and linkages...

Thanks for the help guys. If I ever start this I will for certain make a build thread.

The slave and master cylinders, pilot bearing and all clutch parts are 4 spd items, no problem, but I would try and get the tranny cross member, which should be attached to the tranny when its removed. I dont think the 240 auto cross member is what you want, you need the 5 spd one. The shifter is not the same as the 4 spd one, the rods should be able to be shortened and re threaded easy enough.

I am not sure if I have the expertise to shorten the rods to the correct length. Do you know of any shops that could guide me through this process? I'm sure there is a shop out there that has done this before... Also, the tranny is described as an 82, should I try to source parts from vehicles that are 82 and newer? Does it matter?

Thanks!

at this point the average owner is more informed than your average shop when it comes to these old benzes. There are experts in shops kicking around, depends on where you are. What is your location?


the two most important bits that must go together are the gearbox and shifter. The rods are actually amazingly straighforward to rig up.

the shifter can be locked underneath in the neutral position (there is a small hole that lines up through all levers underneath, and the transmission has 3 levers that can be placed in the neutral position (typically up and down). Then its a matter of connecting levers on the shifter with levers on the gearbox, and making sure they don't interfere with eachother when the gear is thrown. Some trial and error, but not bad.

Ive actually used a single automatic shifter rod before to complete a set of 3. I was missing one for the manual.

You need to access data on the EPC that shows what lever goes to what lever, but after that its pretty simple. The year spread should br no problem, im using a 1974 4-speed with a 1981 4-speed shifter in a 1983 sedan

Anyone taking bets on this being a 190 trans or a 4+1?

+1
I hope they are sending some pics of it before buying. Make sure the starter bulge is on the passenger side.

I asked them so send me photos of the transmission, making sure to get the data numbers in frame... If not a 5 speed, there are more then enough 4 speeds to be had.

I hate to say this...but shortening the rods would be one of the easiest aspects of this project. This is a fairly involved project for even an experienced shade tree mechanic epically without having the doner car close by.