Auto to manual transmission swap, a few questions.

[mathuisella]

So, reassembly...

Got the flywheel on. Torqued to 35NM then done an extra tight turn for 45-60 degrees. they seem really tight now :) I read it somewhere that it should be 30 to 40NM then an extra 90-100 degree turn with a braker bar, but i felt i was going to break something if i tightened any further than 35nm than an extra 50odd degrees.

tightened them up in pattern.

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now to put clutch in

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Lubricating things up....

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now, with the position of the levers on the gearbox, they will be a pain to connect to with the rods after the gearbox is in the car, so i decided to attach now...

The linkage rubbers are 3d printed TPU, Poly-urethane material, just the right amount of give :)

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However, the rods are way too dirty for my liking...

Needs a clean..

Partial clean...

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and now clean...

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oh and i took measurements so i can 3d print the rubber linkage parts for the other end of the rods...

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[merc-304]

Gee thats a massive amount of Lube....others will know more than me but if you havent put the box in yet id say clean 90% of it away.
What type of Lube is it ?

[mathuisella]

Gee thats a massive amount of Lube....others will know more than me but if you havent put the box in yet id say clean 90% of it away.
What type of Lube is it ?

What can i say :P

it's high temp ball bearing greease :)

[mathuisella]

todays update.

time to get the shifter out of the doner 240D car.

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taking the cover trim out.

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out we come

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disassembly

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and clean

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i couldn't for the life of me find my molly Disulphide, so a quick trip down to the store and got some, however, there's no light now. so assembly tomorrow.

[AMG]

So, reassembly...

Got the flywheel on. Torqued to 35NM then done an extra tight turn for 45-60 degrees. they seem really tight now :) I read it somewhere that it should be 30 to 40NM then an extra 90-100 degree turn with a braker bar, but i felt i was going to break something if i tightened any further than 35nm than an extra 50odd degrees.

tightened them up in pattern.

22546800_10212365855954292_557417389_o.jpg

They are stretch bolts.

If you don't tighten them up to the correct spec, they will come loose - in no time flat you'll have a bunch of broken bolts, a flywheel coming out the bellhousing and half a leg sliced open.

or you'll just break your input shaft pressure plate and clutch disc.

follow the specs in the manual, use a long breaker bar.

[mathuisella]

So, reassembly...

Got the flywheel on. Torqued to 35NM then done an extra tight turn for 45-60 degrees. they seem really tight now :) I read it somewhere that it should be 30 to 40NM then an extra 90-100 degree turn with a braker bar, but i felt i was going to break something if i tightened any further than 35nm than an extra 50odd degrees.

tightened them up in pattern.

22546800_10212365855954292_557417389_o.jpg

They are stretch bolts.

If you don't tighten them up to the correct spec, they will come loose - in no time flat you'll have a bunch of broken bolts, a flywheel coming out the bellhousing and half a leg sliced open.

or you'll just break your input shaft pressure plate and clutch disc.

follow the specs in the manual, use a long breaker bar.

I'll get the breaker bar out and torque them the extra 45 degrees in the morning :)

[mathuisella]

okay, flywheel bolts are done, torques up to 35NM and then added 90 degrees with a breaker bar :) they are really snug tight down.

[Ivanerrol]

Too late :boohoo:

http://www.carpoint.com.au/all-cars/pri ... 4153&Cr=19

[merc-304]

Anyone else think the amount of lube on input shaft in pic above is excessive ...and is likely to be thrown around and contanimate the clutch plate ?

[mathuisella]

Too late :boohoo:

http://www.carpoint.com.au/all-cars/pri ... 4153&Cr=19

that's a nice buy depending on what's wrong as why it's " not running"

I took off the excess grease and got the gearbox mounted. Today is raining again so no car work :(

[AMG]

Anyone else think the amount of lube on input shaft in pic above is excessive ...and is likely to be thrown around and contanimate the clutch plate ?

Yeah, wipe it off.

don't need it there. especially on the splines. what you need on the splines is a fine fine smear of silver antisieze and nothign else. use htb on the pivot fork ball and pack the throwout bearing a little (but wipe all excess from the face) and certainly put some on the end of the slave cyl rod in the back of the pivot fork. not an excessive amount.

[tsharkey]

There is a rusty 5 speed wagon over in SA you could use to upgrade your conversion ....

viewtopic.php?f=80&t=12692&p=175928#p175928

[mathuisella]

Okay so gearbox is in place

doing it up....

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next is the custom length driveline.

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then it's time to modify the gearbox mount.

I have 2 mounts, using the one in worse condition as a test.

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fitting it

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and now the test, taking away the jack

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[tsharkey]

Hi - Can I ask why the rear engine mount didn't just bolt in - is the actual chassis different there in the 240D ?

[mathuisella]

Hi - Can I ask why the rear engine mount didn't just bolt in - is the actual chassis different there in the 240D ?

assuming you mean the transmission/gearbox mount ?

the tunnel is more of a "V" rather than a rectangle straight one. there are 4 positions for mounts spaced along the tunnel, this allows for various transmission and engine combinations. However, with this combination of engine being longer than the 240d and the transmission being shorter than the automatic, it put it into position 2 along the tunnel, rather than position 1, so the mount i had was a bit too wide/long.

[mathuisella]

So, if it counts, today i put fresh oil in the diff and gearbox

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[mathuisella]

Today's work

Here's the shifter that's being a pain in the arse.

Got it together and put it in the car. Although not the cleanest as i would've liked, but as you all know i'm very short on time to get this done.

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under the car, put in a welding rod to keep the shifter in neutral position to get all the nest parts done

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as you can all see, the rods are all too long

time to mark, cut weld, grind and paint





before welding, making sure it all lines up nicely

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in the vice


a quick snap shot of one of the tack welds before i go around and finish it up

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all 3 welded, not the prettiest by a long shot, but nice and strong

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painted with some paint that i had for a previous car that should keep the weather off them

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greasing these up with moly grease, looks like they haven't been greased since factory

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Next part is to make bushings for the shifter end



Here we have my 3d printer making them with some TPU flexible filament.

ydg6v.jpeg

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:)

[mathuisella]

rubber pieces in :) ( could redesign them to be a better fit, but at this stage as long as things work asap i'm happy

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bonnet latch sucks with this home repair from previous owner...

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replacement

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all lubed up

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it closes and opens so beautifully now

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Fuel tank level sending unit....

a bit dirty...

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putting in new wire and cleaning it up

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cleaned and reassembled

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i tried to do clutch bleed today, but it quite simply is a 2 man job :(


up next is the neutral safety switch bypass ( considering making this a secret momentary switch as an immobiliser of sorts, which would never be found by anyone not super familiar with a 30 to 40 year old Mercedes ;) )

[mathuisella]

https://www.youtube.com/watch?v=WoRXRgwNXJM

SHE RUNS :D

edit:

gears shift really well, like a well cleaned and oiled bolt action rifle. :)

Now to do the general maintenance items and then get her back on the road.

[gazman]

Well done congratulations :occasion5:

[mathuisella]

Well done congratulations :occasion5:

Thank you :)

now i need to bleed the brake system as the brake pedal isn't building pressure.

Also to find the 1 or more vacuum leaks in the system.

Bolt every panel and fitting back together and just tidy the whole car.

[AMG]

Good Job.
What's the next project ? :occasion5:

[mathuisella]

Good Job.
What's the next project ? :occasion5:

HAHA nah, sticking with this car.

i like the w123 series, old enough with the classic looks, yet new enough to handle highways without stressing the motor and having the diesel + manual transmission is the combination i love :)

Also enjoy the lack of electrical in comparison to newer cars :)

[mathuisella]

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[AMG]

Signalrot :love4:

[mathuisella]

Signalrot :love4:

Just for you :)


I got new tyres today :D

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[AMG]

There's something about a Signal Red Mercedes. Can't quite put a finger on it - but anyone who's owned one knows what I mean.

[mathuisella]

There's something about a Signal Red Mercedes. Can't quite put a finger on it - but anyone who's owned one knows what I mean.

It's an awesomely vibrant colour that looks great.

I've finished the transmission conversion and now working on other aspects of the car. Right now it's the vacuum system

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[Tony From West Oz]

There is a non-return valve in the line from the main vacuum line from the vacuum pump to the CL system. It should be before the split to the vacuum tank and the door feed. The vacuum tank has a yellow line.

[unheardofinstruments]

TYou make me want to get a 3d printer, are you up for printing the bushes for me? Nice bunch of photo's and thanks for the log as I am putting a manual in my 300td project this really helped, thanks.

[mathuisella]

Glad this thread has been useful :)

Where abouts are you located ?

I've moved house and haven't set up my 3d printer yet.

[julian]

I’m gearing up to do a similar project and would be keen to pick your brains and maybe also get some printing of bushes if you kept the data.

[mathuisella]

:)

happy to help