I had my transmission replaced & when I got it back it kept popping out of reverse. That saga is here:http://www.peachparts.com/shopforum/diesel-discussion/363557-trani-clutch-drive-shaft-1983-240-manual.html

I was told that my shifter "bushing" needed replaced. (note the singular! I have since learned it's not singular)

I'm going to give as much detail here as I can think of so please ignore what's not important. Note that when I got the car back(late January) it was popping out of reverse(couple of days), then I would hold it in reverse & it was good for a few days, but then it would just grind(I only did this a couple of times before I just quit trying b/c I didn't want to ruin reverse) so I stopped parking it anywhere where I needed to back up.

I finally had a friend help me with checking things out today. Without getting into the actual shifter, because he wanted to be sure the issue wasn't really with my transmission first, we disconnected the shifting rod from the shifting lever. What we discovered is that the rod will push it into reverse but the shifter won't because the rod appears to be to short. We adjusted the end of the rod that connects to the shift lever as far out as it will go & still need, at least, another inch.

I still have my old transmission in my trunk(I knew I hadn't found a spot for it yet for a reason) & he checked how far the transmission lever moves on the old one versus the new one & the difference is huge. The old transmission reverse lever moves 1 3/4" & the new one moves 3"(both approximate, but very close). 1-2 & 3-4 work just fine with its current transmission(and with the old one).

I had motor mounts & a new clutch put in when the trans was put in.

With the shifter rod hooked up my shifter won't even touch the silver button that turns the reverse lights on(I didn't check any of that while the shift rod was disconnected because we didn't realize that issue until later). We also noticed that the shift lever is hitting the back of the square hole that it comes through to connect to the rod. If it weren't hitting that it might have enough room to move all the way to engage reverse.

SO...what's up with this transmission & its reverse??? Or, is there something else that's REALLY causing this problem that I'm just not realizing?

Did you replace the transmission with a different design? The aluminum housing is compatible with the old iron transmission but the shifter rods are different along with some of the clutch parts.

Did you find a 5 speed?

__________________
John HAUL AWAY, OR CRUSHED CARS!!! HELP ME keep the cars out of the crusher! A/C Thread
"as I ride with my a/c on... I have fond memories of sweaty oily saturdays and spewing R12 into the air. THANKS for all you do!

My drivers:
1987 190D 2.5Turbo
1987 190D 2.5Turbo
1987 190D 2.5-5SPEED!!!

1987 300TD
1987 300TD
1994GMC 2500 6.5Turbo truck... I had to put the ladder somewhere!

The old Iron Box transmissions have 3 shafts that come out the side of the box.
The 3 shift Levers clamp onto these rods with a Bolt that keeps the levers tight.
There are Splines that the two lock into each other on the shafts.
check to see if the Bolt is loose. These levers as I remember point straight up.

The all one piece box is Aluminum. Also has 3 levers.
The levers are held with a bolt going into the center of the lever.
Make sure this bolt is tight.
2 levers point down and reverse as I remember points up..

As mentioned, the two style of boxes use different Shift Rods as the lengths and bends are different.

There is an adjustment under the Shifter assy. Each shift lever pointing down has a hole in the side. Looking at the bottom of the shifter assy., there is an upside down "V" in the plastic.
Stick a Nail or Drill Bit through the "V" and the three levers to the "V" on the other side.
This lines up the shifter in the natural position.

Make sure the transmission shift levers are in the natural position.
Attach the Shift Rods to the Transmission end, then adjust the screw on end to the shifter assy., levers.

Remove Nail or Drill Bit.

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

Thank you for the info. I have finally had a chance to get back under the car.

On both of the transmissions the levers are all oriented the same. 2 in one direction, one in the other direction. I put a magnet all over both & it wont stick anywhere except bolts...i dont know if this is a good test for the iron trans or not. I just dont get how there could be that much difference in the throw from one trans to the next if they are the same style. The friend that helped me check this out said we could modify the length of the rod. Good idea?

I called another shop quite a ways from here & he said the shifter could be worn out as well as bushings & need replaced. Would that really make such a dramatic difference?

Any thoughts? Thanks!

Here are a couple links from STD showing the Iron Box and the all one piece Aluminum case.

This first one is the Iron Box, notice it has an aluminum Bell Housing. This bolts onto the box.

http://www.superturbodiesel.com/std/attachment.php?aid=793

This next one is the all one piece Aluminum case.

http://www.superturbodiesel.com/std/attachment.php?aid=794

The Iron Box was used thru 1980 240D.
The all one piece was used in the 240D 82/83

Not sure on the 81 240D, I have seen both, so maybe 81 was the change year.

The Shift Rods are Transmission specific.

Your whole problem probably is in your Shifter assy., with worn bushings.
There is a rebuild kit for the Shifter.

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

Thank you for the pictures. They are both the same transmission-aluminum case.

I will call about the kit, I couldn't find it in the listed parts.

phc:

You may wish to think about the question you were asked by vstech in post #3. Is your replacement trans in fact a five-speed? If it is, the lever which you are identifying as the "reverse" lever, is actually the 1-R lever, or the 5-R lever, depending on which side of the gate (L or R) reverse is located on, and the travel will, indeed, be almost twice the amount required for reverse alone; exactly what you are experiencing.

Iam sure the 5 spd would be a bit longer? than the 4-spd?

http://www.superturbodiesel.com/std/attachment.php?aid=796

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

Can you post a pic of the trans you have installed?

__________________
John HAUL AWAY, OR CRUSHED CARS!!! HELP ME keep the cars out of the crusher! A/C Thread
"as I ride with my a/c on... I have fond memories of sweaty oily saturdays and spewing R12 into the air. THANKS for all you do!

My drivers:
1987 190D 2.5Turbo
1987 190D 2.5Turbo
1987 190D 2.5-5SPEED!!!

1987 300TD
1987 300TD
1994GMC 2500 6.5Turbo truck... I had to put the ladder somewhere!

Ok, now I am really freaking out...thank you so much

I thought vstech in #3 misunderstood the trans I needed for this car-obvious misunderstanding...

Where on the bell housing can I find ID markings to identify what came out & what went in?

On a 5-speed what is the combo of gears? On the one that came out my reverse is left & forward. I don't understand what the "gate" is. As for pictures, I don't think I need to post the pic b/c the trans(I think) looks just like what was posted by charmalu in #6 here:

http://www.superturbodiesel.com/std/attachment.php?aid=794

However...I will put it up today & double check that it isn't what's posted in #9, because I scooted my scrawny butt under it without putting it up on anything yesterday & just used by hands to find the reverse lever. I will verify this morning which one it is. I'm actually hoping it's the 5 speed because that would make sooooooooo much sense

I talked to my brother last night & he suggested that it is possible that this trans is from a car that wasn't originally for the American market & that could be the difference in the throw...maybe? Thoughts on that?

When I called Pelican Parts to find out about the rebuild kit(& blathered on about my troubles) I was told to call back Tues morning to talk to Mike S. who has done trans rebuilds. Does anyone have any suggestions on who else I might talk to? The more suggestions the better, and I truly appreciate all the help! Really, I am just beside myself at how helpful everyone has been. I wish all of you were my neighbors, and not just b/c we are all MB owners

There is no # on the Bell Housing, it will be down low on the side of the gear case like this. this trans is a 707.404

Yours will be a 707.xxx

I have several spare trans, I`ll get the #`s and post what yours might be.

http://www.superturbodiesel.com/std/attachment.php?aid=1840


The "Gate" you mentioned, is the Shifter Box also referred to as a Shift Gate.

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

I believe Charlie means to say neutral (not natural).

__________________
[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.

I don't think there is any difference in the trannys for us and the world on 240 sticks.

__________________
[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.

I got under the car again(on jack stands!) & it is the 4 speed-reverse lever points up.

After rereading over everything I checked to see where the adjustment was for the shift levers. When I found it I noticed that there is a lot of sideways play in the reverse lever, +-1/2". It is actually resting against the lever next to it when I quit moving it. Will that be fixed by replacing the bushings in the shifter or is there something else that needs to be replaced or is that just normal?

Should I do the adjustment AFTER I replace the bushings?