I was looking through the startech site and didn't find anything on the 4 speed manual gearbox. Did I just miss it or can that be found somewhere else?

I'm looking for a full teardown/rebuild procedure or at minimum exploded views of everything. Does anyone know where info on rebuilding the 4 speed can be found?

Good luck.
When you locate one, let us know. I have never seen a 4-spd manual FSM'
That doesn`t mean there isn`t one floating around somewhere.

The Haynes manual for the W123 has a section on the early style Iron box.
But nothing for the later all one piece Aluminum box.

The Haynes manual for the W201 190E has an excellent section on the 5-spd manual trans.



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

Have a look at this; Volume 1 of the W114/115 manual contains the Iron 4-speed procedures.

http://www.peachparts.com/shopforum/mercedes-used-parts-sale-wanted/376577-w114-w115-factory-service-manuals-1970s-general-maintenance-manuals-sale.html

Is yours the iron case Mercedes-made box or the aluminum case Getrag? If it's the Getrag you might try Googling for it as a "Getrag" rather than as a Mercedes piece. You can bet that transmission repair shops can get info on them somewhere, maybe an online shop manual service. If it's the iron case the previous post ought to help.

Dan

Cheap enough from a wrecker or member than dealing with a serious issue in one. They are pretty rugged transmissions. It is not that they are a particularily hard transmission to fix but parts are probably high in cost unless you get them out of another transmission used.

I never tore into one of these but remember reading about them in a service manual years ago.

thanks, frank, that is great to know.

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'77 240D, 504H, OM617.952, etc.

I've got the aluminum getrag trans. Bought a new set of snap ring pliers and the 30mm socket for the output shaft nut. Going to pull it apart.

We need the model numbers off the transmission case to help you.

.

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The aluminum late model 4 speed and the 201 5 speed and in one of the G-wagon 5 speed are similar. 717.411 717.43x 716.2 Many parts are interchangeable and they are of the same design. I am sure this manual I have will help. It is the FSM but it is photocopied to CD so the quality of some pictures is low. It should be quite helpful. You will have to PM me and I can send a link to your email.

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Chris
84 280sl
82 300d euro

Thanks for the replies. My trans is a 716 210.

123 260 12 01 716 210 00245100

Stuck at disassembly. I'm assuming this snap ring needs to be removed before that intermediate plate can be removed. Before I mar the up face of that plate anymore than I already have, does anyone know what the trick to removing this snap ring? I have quality snap ring pliers but it seems the ring cant be expanded enough to be removed, or elevated enough to get anything under on which to pry against.

I'm just going by my generic knowledge, NOT experience with this trans.

I'll guess that that snap ring positions the shaft and does not retain it so it probably doesn't need to come out to pull the shaft (looks like the mainshaft in the pics). Have you pulled the output shaft case yet? Good chance that once everything is removed the shaft in question slides out the front with that snap ring in place. If you look at the case that bolts up to the flat surface in the pics you'll likely see that the snap ring is retained by being trapped between the snap ring groove and that front case.

Anyhow, if you come at the trans from the other end you may find that once you clear out the other shafts and gears the (what appears to be) mainshaft will come right out. More than likely the countershaft and reverse mechanism will have to come out first if what I'm looking at is what I THINK I'm looking at.

Again, I'm just going by generic knowledge here so I'm making a disclaimer.

Dan

Turns out I was being too gentle. I just had to hit it harder with the deadblow and it slid off.

Excellent! Looks like the gears all load from the rear. Rock ON! (I know nobody says "rock on" anymore but I'm old.)

Dan

Yep - those ball bearing gearboxes are harder to pull to bits. Not as easy as the tapered roller bearings...

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1992 W201 190E 1.8 171,000 km - Daily driver
1981 W123 300D ~ 100,000 miles / 160,000 km - project car stripped to the bone
1965 Land Rover Series 2a Station Wagon CIS recovery therapy!
1961 Volvo PV544 Bare metal rat rod-ish thing

I'm here to chat about cars and to help others - I'm not here "to always be right" like an internet warrior



Don't leave that there - I'll take it to bits!