My son and I have graduated from MB 101 and are one week into MB201. Having gained great confidence in learning valve adjustments, alternator replacements, brake line replacements and the like, we figured we'd try an engine swap.

Oh boy.

So far, we've removed a siezed engine from a 240D. In addition, we've removed a 300D engine from my daughter's totaled car. Our plan is to put the 300 turbo in the 240 manual.

Our first holdup has come as a general observation that the shaft (don't know the exact term) contained in the bell housing is not the same in both cars. The teeth are different in form and in number. My assumption then is that this shaft from the 240 tranny will not mate with the rear of the new engine.

Does anyone have any experience with this? Can it be swapped as well? In searching through various threads, I can't seem to locate an answer to this problem.

Thanks

Don

__________________
DAILY DRIVERS:
'84 300DT 298k (Aubrey's)
'99.5 Jetta TDI IV 251k (Julie's)
'97 Jetta TDI 127k (Amber's)
'97 Jetta TDI 186k (Matt's)
'96 Passat TDI 237k (Don's
'84 300D 211k Mint (Arne- Undergoing Greasecar Conversion)

SOLD:
'82 240D 229k (Matt's - Converted-300DT w/ 4 speed

I am driving a 1979 240D with a 1981 300 Turbo under the hood and 4 speed manual transmission. I recommend:
1- Use the flywheel from the 240.
2- Have the drive shaft machined and shortened to compensate for the extra length of the new engine.
3- Try to locate a 5 speed manual transmission fron a european model.

Good Luck,
Moftaki

1987 190D 2.5 201K miles
1979 240D w. 300Dt 149K miles

Do a search on 'manual transmission swap' for info on this topicl. You can use the 240d manual flywheel and clutch, but the 300d with a manual transmission did use a different flywheel. Such a flywheel is not easy to find in the US since few were imported. You will have to shorten the shift linkage rods to compensate for the extra cylinder. I believe one of the posts in a previous thread says they need to be shortened 4 inches exactly.

Is your euro 300d parts car manual or auto?

__________________
1977 300d 70k--sold 08
1985 300TD 185k+
1984 307d 126k--sold 8/03
1985 409d 65k--sold 06
1984 300SD 315k--daughter's car
1979 300SD 122k--sold 2/11
1999 Fuso FG Expedition Camper
1993 GMC Sierra 6.5 TD 4x4
1982 Bluebird Wanderlodge CAT 3208--Sold 2/13

Kerry:

The good news is that I'm actually combining 3 cars. My euro parts car is manual which gives me the shortened drive shaft. I also have the flywheel from there as well.
However, I already sold the shifting linkages which is a bummer. That was before this project was ever dreamed up.
As this is all new territory for me, it is step by step learning.

Don

__________________
DAILY DRIVERS:
'84 300DT 298k (Aubrey's)
'99.5 Jetta TDI IV 251k (Julie's)
'97 Jetta TDI 127k (Amber's)
'97 Jetta TDI 186k (Matt's)
'96 Passat TDI 237k (Don's
'84 300D 211k Mint (Arne- Undergoing Greasecar Conversion)

SOLD:
'82 240D 229k (Matt's - Converted-300DT w/ 4 speed

You are a very brave guy.....
It is really great you have the 300 flywheel... people have used the 240 flywheel with no ill effects reported... but the FSM specifically says NOT to....
I don't guess you are taking digital pictures of your progress.. and particularly of Problems as you go along ?

My problem with my digital camera is that on the lowest pix count it still is too high for the forum. Therefore, someone always has to adapt it. But yes, I'll be doing some of that for posterity sake and also for help.

Since our 300 was totaled, it wasn't a big deal to attempt it. Whether or not it will actually work is a matter of great curiosity.

Don

__________________
DAILY DRIVERS:
'84 300DT 298k (Aubrey's)
'99.5 Jetta TDI IV 251k (Julie's)
'97 Jetta TDI 127k (Amber's)
'97 Jetta TDI 186k (Matt's)
'96 Passat TDI 237k (Don's
'84 300D 211k Mint (Arne- Undergoing Greasecar Conversion)

SOLD:
'82 240D 229k (Matt's - Converted-300DT w/ 4 speed

If you are taking them in Jpeg then you could sign up for the free Photoisland.com service to ' hang ' them... so others could go view them.... They have changed the rules a couple of times since I signed up.. so I am not sure of the current status... but at one time I had 100 megs of space to use.... free..... and could invite any number of visitors.... that is how I shared the pics of the potential get together sites last year...
If they have restricted the number of visitors per day.. you could still use it to post the pics which you need altered . They also have some good free software for other aspects of photosharing...

diesel don,

What luck that you have the correct flywheel. Make certain that when you swap the 300D flywheel onto the crank that you line up the mark on the flywheel with the mark on the crank, that way everything is balanced from the git go.

You mentioned that the splines on the clutch shaft are different. No problem as there were two different clutch discs available and you just have to order the disc that has the corresponding number of splines. It seems most of the ones I've done were ten splines.

You should be able to find more linkages but will have to shorten them by exactly four inches as already mentioned. The tranny support will bolt righ in if it's the single bolt unit but if you have the double bolt one, you'll have to add a 1/4 x 1 1/2 plate to either side and drill for hole openings so it will be wide enough to bolt up further back on the tranny tunnel.

Good going, you'll love the result.

I've just found two 5 speeds in Europe and my son is there to pick them up. Really excited about them. May be able to import them for others along with flywheels.

Ben

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www.reproduce100s.com

Ben:

This is very helpful. Tomorrow I'll dig some more and see how far I get. My son doesn't turn 16 until June 8, so we have some flexibility. But we yanked two engines in two days so we're having a blast.

I need to bring a camera home from work and keep you guys posted.

Don

__________________
DAILY DRIVERS:
'84 300DT 298k (Aubrey's)
'99.5 Jetta TDI IV 251k (Julie's)
'97 Jetta TDI 127k (Amber's)
'97 Jetta TDI 186k (Matt's)
'96 Passat TDI 237k (Don's
'84 300D 211k Mint (Arne- Undergoing Greasecar Conversion)

SOLD:
'82 240D 229k (Matt's - Converted-300DT w/ 4 speed

Bear with me as I clarify some basics:

Donor Car #1 '84 300DT (donating engine)
Donor Car #2 '83 300D euro with MANUAL 4 speed (donating flywheel, driveshaft)
Final Car #3: '82 240D manual

Final Goal: Turbo 300 engine into 240


QUESTIONS FOR CLARIFICATION:

1. The torque convertor attached to the flywheel ring gear on the 300 auto tranny must come off right and be replaced with the flywheel from the 300 manual ???

2. I must find a clutch disc that fits the splines on the cluth shaft. I must find it either from the euro 300 manual, the 240 manual or order it right?

As for the motor mounts, transmission mount cross member, driveshaft, etc, I think I'm up to speed.

Thanks much

Don

__________________
DAILY DRIVERS:
'84 300DT 298k (Aubrey's)
'99.5 Jetta TDI IV 251k (Julie's)
'97 Jetta TDI 127k (Amber's)
'97 Jetta TDI 186k (Matt's)
'96 Passat TDI 237k (Don's
'84 300D 211k Mint (Arne- Undergoing Greasecar Conversion)

SOLD:
'82 240D 229k (Matt's - Converted-300DT w/ 4 speed

Don't bother answering the questions, the riddle was mostly solved today.

Thanks

Don

__________________
DAILY DRIVERS:
'84 300DT 298k (Aubrey's)
'99.5 Jetta TDI IV 251k (Julie's)
'97 Jetta TDI 127k (Amber's)
'97 Jetta TDI 186k (Matt's)
'96 Passat TDI 237k (Don's
'84 300D 211k Mint (Arne- Undergoing Greasecar Conversion)

SOLD:
'82 240D 229k (Matt's - Converted-300DT w/ 4 speed

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__________________
Never a dull moment at Berry Hill Farm.

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__________________
Never a dull moment at Berry Hill Farm.

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__________________
Never a dull moment at Berry Hill Farm.

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__________________
Never a dull moment at Berry Hill Farm.