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#1
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240 Trans Swap
Everyone,
I've seen a zillion posts about transmission swaps with all kinds of great technical information. However, I can't seem to find some more simple answers. I have a 77 240D on which I'm starting to think about swapping the poor but exuberant automatic transmission for a manual. My car came with a 722.117. I'm told by MB Classic Center that, if it were shipped with a manual, it would have been 716.005. How tight do I need to stick to that .005 transmission? Since it's all vacuum, I don't want to stray too far. |
#2
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Why do you worry so about the vacuum? It affects nothing on the manual, so if you have a line going to the automatic, just plug it off. Either of the two 4 speeds will work with no problems and no vacuum. Vacuum on that old a model would have been applied only to cruise control, P Brakes, door locks and engine stop. If those items work now, they will work as well with the new transmission. If you are looking for parts for the swap I have them all.
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Junqueyardjim Christianity, if false, is of no importance, and if true, of infinite importance. The only thing it cannot be is moderately important. C.S. Lewis 1983 Mercedes W123 240D 4 Speed 285,000 on the road with a 617 turbo, beautiful butter yellow, license plate # 83 240D INDIANA 2003 Jaguar Type X, AWD. beautiful, good mileage, Mom's car, but I won't let her drive it! |
#3
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If my info is correct, yours would have had the cast iron case Mercedes-made manual - the later cars (not sure of the year of the change) had a Getrag-sourced aluminum case 4 speed. I have the Getrag and it's been perfect - I pilfered the trans and linkage from an '83 240D.
It should be a pretty straightforward swap with the hard parts being: 1) Find out if your current flywheel is neutral balanced or not. Before removing the current flywheel be sure to mark it so you know its orientation. Take both flywheels to a balancing shop (most towns of any size will have a company that does industrial balancing) and have them check balance and mark the manual flywheel to match the automatic one. Align your marks and off you go. My engine/flywheel combination was, evidently, neutral balanced so I got away with it but so far I have not been able to find any info on which combos are neutral balanced and which are not. If I had known a bit more when I did mine I would have done the procedure as detailed above. 2) You'll need to transfer all the clutch bits. Remember that the clutch linkage is hydraulic and on the M-B used the brake reservoir as a fluid source (I got around that in my hybrid Chevy/Mercedes system). These are notoriously difficult to bleed but most of us have had the best luck pressure bleeding it from the slave back up to the master - I use a veterinary syringe filled with brake fluid that forces fluid up to the master as I push the plunger. With an all-Mercedes system the guys say the factory instructions work pretty well. 3) The actual installation is pretty straighforward - just nuts and bolts. Make sure your rubber driveshaft biscuits and such are in good shape - again, I don't use them so I don't have any insite on those details. Dan |
#4
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Is your 77 a 123 ?
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1980 240d , chain elongation, cam marks reference: http://www.peachparts.com/shopforum/showthread.php?threadid=10414 http://www.peachparts.com/shopforum/diesel-discussion/305365-9-degrees-chain-stretch.html evap fin cleaning: http://www.peachparts.com/shopforum/showthread.php?t=156207&highlight=evaporator A/C thread http://www.peachparts.com/shopforum/diesel-discussion/297462-c-recommendations-mb-vehicles.html |
#5
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Yes, it's a 77 W123
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