Shifting Grind Manual Transmission
 

1991 190e 2.6 manual

I noticed it was a little difficult to get it in reverse a few times, then after a few days I tried to drive and putting it in reverse was very hard, and hand to grind it to get it engaged. First and second were grinds too. I fought hard to get it into reverse twice, first three times, and second twice, had to really fight to grind through to engage it, but I had no choice.

When I press the clutch it's just free until I get to the very last 10% or so, it's like it's not catching anything until the very bottom, and then probably not enough.

Questions/best guesses:

How much damage did I do grinding into 1, 2 and reverse a few times?

Does this sound like a clutch, transmission, or something else?

How do I troubleshoot? Is transmission fluid the first thing to check or is this definitely indicative of a clutch problem? I think on the manual you have to get under the car and open the "in" hole and if nothing comes out it's low so then you drain through the "out" hole and refill with some kind of pump?

Thanks for your help guys!

Sounds like a clutch problem to me. I've never had a manual Merc but I assume its a hydraulic clutch like my Supra and when that started failing the clutch felt like poo and wouldn't disengage properly. I also had this problem when a clutch fell apart on a truck.

You probably didn't do anything horrible to the trans but you did take some life out of the synchros. I'd fix the cause which is likely a clutch or shift linkage problem, change the fluid, and drive it.

Edit: to be specific my issue was the slave cylinder was leaking.

190:

First check the fluid level in the rear section of the brake reservoir. The clutch tap is the highest, and when the fluid level drops the clutch master cylinder draws air.

My money is on the slave cylinder failing. My dearly departed 87 300E had the same symptoms and it was the slave.

This. The clutch isn't fully disengaging. On a hydraulic clutch this happens most frequently because the fluid is low. Fluid being low can be from the slave failing (common), the master failing (a bit less common, but it's happened to me), or the brake hydraulics leaking.

...had a similar problem ten years ago... turns out the pushrod on the slave had worn and mushroomed over, so not enough stroke to fully disengage the clutch causing it to drag and subsequent hard shifting.

Check fluid level as stated. If that's okay, it's time to remove the slave for inspection. I posted a thread on the subject, including removal/installation tips and how to bleed the clutch system with a new slave.

http://www.peachparts.com/shopforum/tech-help/94805-201-clutch-slave-cylinder-swap-post-mortem.html

Duke