I'll be following the tutorial on Diesel Giant's web page. Does anyone have any tips or suggestions to offer that would add to what DG has already posted?

One hang up that I can see coming is replacing the metal sleeve with a plastic one. Is there a special tool for that procedure? Also, DG doesn't mention disconnecting the transmission from the drive line, will I need to do that to get the transmission low enough for access to the B2 piston? Thanks

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'81 300SD

I had no issue with the job when I did it on my SD.

PRESSING THE COVER BACK IN IS VERY DIFFICULT.

have a prybar handy with wood screwed to it for leverage pressing against the spring.

You need to lube the o rings with trans fluid, or petroleum jelly before attempting install... snags, or binding damages them and will leak...

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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!

Maybe it wasn't so difficult for DG because the piston was used.

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'81 300SD

I can't remember, but one of the pistons has a spring against the cover (B1?), and the other, no spring (B2?). I did this job, and it was not hard at all. I had to make a tool to pull the sleeve, and it worked like a charm. There is a thread here somewhere, I will see if I can find it. The challenge is getting the "dogbone" to stay in the right place while inserting the piston in the bore. I used red grease. You won't know if you got it right unless you remove the valve body to see up inside.

Here it is: http://www.peachparts.com/shopforum/diesel-discussion/385909-300td-b2-piston-replaced-still-no-forward-movement-3.html

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All Diesel Fleet
1985 R107 300SLD TURBODIESEL
2005 E320 CDI (daily)

LOTS of parts for sale!


EGR block kit
http://www.peachparts.com/shopforum/diesel-discussion/355250-sale-egr-delete-block-off-plate-kit.html

1985 CA emissions 617 owners- You Need This!
Sanden style A/C Compressor Mounting Kit for your 616/ 617 For Sale + Install Inst.

Sanden Instalation Guide (post 11):
http://www.peachparts.com/shopforum/diesel-discussion/367883-sanden-retrofit-installation-guide.html

I'm having a hard time getting the cap off. It looks like the retaining ring came off at some point. Either that, or I just can't see the ring and get a screw driver on it. Should the cap come off easily?

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'81 300SD

Okay, so I got the cap off once I saw that you have to push the cap in to see the clip.

I removed the piston, and as far as I can tell it's fine. The springs in the old piston have the same amount of resistance as the springs in the new piston. Everything in the cylinder looks clean and tight. Could it be a bad band that's taking away first gear?

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'81 300SD

Ive crossed over to ROLLGUYS link on the above thread .He found the valvebody to be bad on his transmission and its conclusion.Might be your case here.

I'm taking the car to a very good transmission shop called MB exchange in Fremont CA. They charge $1800+tax to rebuild and install the transmission.

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'81 300SD

It would be nice to know why yours failed. Maybe with a forensic examination, they can determine the cause of the failure. Please let us know. Thanks, Rich

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All Diesel Fleet
1985 R107 300SLD TURBODIESEL
2005 E320 CDI (daily)

LOTS of parts for sale!


EGR block kit
http://www.peachparts.com/shopforum/diesel-discussion/355250-sale-egr-delete-block-off-plate-kit.html

1985 CA emissions 617 owners- You Need This!
Sanden style A/C Compressor Mounting Kit for your 616/ 617 For Sale + Install Inst.

Sanden Instalation Guide (post 11):
http://www.peachparts.com/shopforum/diesel-discussion/367883-sanden-retrofit-installation-guide.html

Here is my 722.3 valve body rebuild tutorial if anyone is interested at taking a stab at it. I have done a few of these already and it is shocking how much material gets built up in them!

https://www.youtube.com/watch?v=h9thWDLR5yo&t=1s

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1991 F250 super-cab 7.3 IDI. (rebuilt by me) Banks Sidewinder turbo, hydroboost brakes, new IP and injectors.
2003 S430 - 107K
1983 300SD - Tanoshii - mostly restored ~400K+.
1983 300SD - Good interior. Engine finally tamed ~250K.
Monark Nozzle Install Video - http://tinyurl.com/ptd2tge

https://www.youtube.com/watch?v=vTzCjT4keUQ
This video link shows b2 piston cap removal at 24.10 time in the video.

You are limited to pushing on the part of the band that you can see through the middle of the hole that the Piston came out of. You will see a rectangular piece of metal with a dimple that the rod/dog bone goes in to.
Push on that dimple and see if it springs back into position.


Not a definitive test but that is all I have read of anyone doing.

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84 300D, 82 Volvo 244Gl Diesel

As the report back might be informative to the DIYers he now puts it in the hands of the claude almighty ,he runs the trans shop.Im a gambler and will say its what rollguy went through on his trans ,just a step less if his example pays heed .I like the fact that these guys paved through this project to get us answers as we may have never realized otherwise. I would really like to start my own trannie b2 piston drama series so I wont feel left out.If this happens eventually to 70% of the 617 powered models it could reap a big difference in the amount of cars that are kept from the junkyard if this stays DIY able .Some owners might give up entirely and send it to the bonesyard.If its other than the b2 piston it will give me a next step if I move forward instead of a trans shop,I do have a good one lined up but not nearly as cheap as what you guys in California have available.Ill shop around more but those sound like good numbers to have a service worry Transmission.

They gave me a rebuilt transmission off of the shelf. They weren't even going to bother opening up a transmission with 300K on it. Sorry I can't give you any information on the cause of my issue.

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'81 300SD

They generally do this as a rule ,to fix one problem it might fix that one but 2 more may arise and they start chasing their tale to figure it out.For this thread and the chase down I might be able to support if my b2 piston is good and the shop Ive chosen does the job ,he rebuilds at his location.Try to get photos for the look of this issue.