Auto to manual transmission swap, a few questions.
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Re: Auto to manual transmission swap, a few questions.
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.
now to put clutch in
Lubricating things up....
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 :)
However, the rods are way too dirty for my liking...
Needs a clean..
Partial clean...
and now clean...
oh and i took measurements so i can 3d print the rubber linkage parts for the other end of the rods...
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.
now to put clutch in
Lubricating things up....
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 :)
However, the rods are way too dirty for my liking...
Needs a clean..
Partial clean...
and now clean...
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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Re: Auto to manual transmission swap, a few questions.
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 type of Lube is it ?
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Re: Auto to manual transmission swap, a few questions.
todays update.
time to get the shifter out of the doner 240D car. taking the cover trim out.
out we come
disassembly and clean
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.
time to get the shifter out of the doner 240D car. taking the cover trim out.
out we come
disassembly and clean
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.
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Re: Auto to manual transmission swap, a few questions.
mathuisella wrote: ↑Sun 15 Oct, 2017 5:10 pm 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.
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Re: Auto to manual transmission swap, a few questions.
AMG wrote: ↑Thu 19 Oct, 2017 9:14 pmmathuisella wrote: ↑Sun 15 Oct, 2017 5:10 pm 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 :)
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Re: Auto to manual transmission swap, a few questions.
okay, flywheel bolts are done, torques up to 35NM and then added 90 degrees with a breaker bar :) they are really snug tight down.
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Re: Auto to manual transmission swap, a few questions.
Current
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Re: Auto to manual transmission swap, a few questions.
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 ?
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Re: Auto to manual transmission swap, a few questions.
that's a nice buy depending on what's wrong as why it's " not running"Ivanerrol wrote: ↑Sat 21 Oct, 2017 12:28 pm Too late :boohoo:
http://www.carpoint.com.au/all-cars/pri ... 4153&Cr=19
I took off the excess grease and got the gearbox mounted. Today is raining again so no car work :(
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Re: Auto to manual transmission swap, a few questions.
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.
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Re: Auto to manual transmission swap, a few questions.
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
viewtopic.php?f=80&t=12692&p=175928#p175928
W123 1981 300TD - Family Kid mover
W202 1998 C250D Factory OM605A Turbo - Partner's daily driver
W123 1982 300CD Retro fitted OM617A Turbo - Mine
W123 1984 300TD English 5 Speed Manual
W123 1982 300TD Factory OM617A Turbo (Hans) - Project
W123 1982 300D - OM617 NA (Hektor) - Son's
W123 1985 230TE - Brother's
W123 1985 300D - Sister in Law's
1962 S-Series Valiant (Tho Daimler & Chrysler divorced, still part of the extended family)
Past benzes
W114 1969 250CE - PO put in an M110 transplant and nearly sent me around the bend
W123 1981 300TD - "Matilda" - RIP hit front side & rear but left my brother + niece A-OK
Current Projects
Coupe restoration, Turbo Wagon freshen up
W202 1998 C250D Factory OM605A Turbo - Partner's daily driver
W123 1982 300CD Retro fitted OM617A Turbo - Mine
W123 1984 300TD English 5 Speed Manual
W123 1982 300TD Factory OM617A Turbo (Hans) - Project
W123 1982 300D - OM617 NA (Hektor) - Son's
W123 1985 230TE - Brother's
W123 1985 300D - Sister in Law's
1962 S-Series Valiant (Tho Daimler & Chrysler divorced, still part of the extended family)
Past benzes
W114 1969 250CE - PO put in an M110 transplant and nearly sent me around the bend
W123 1981 300TD - "Matilda" - RIP hit front side & rear but left my brother + niece A-OK
Current Projects
Coupe restoration, Turbo Wagon freshen up
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Re: Auto to manual transmission swap, a few questions.
Okay so gearbox is in place
doing it up....
next is the custom length driveline.
then it's time to modify the gearbox mount.
I have 2 mounts, using the one in worse condition as a test.
fitting it
and now the test, taking away the jack
doing it up....
next is the custom length driveline.
then it's time to modify the gearbox mount.
I have 2 mounts, using the one in worse condition as a test.
fitting it
and now the test, taking away the jack
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Re: Auto to manual transmission swap, a few questions.
Hi - Can I ask why the rear engine mount didn't just bolt in - is the actual chassis different there in the 240D ?
W123 1981 300TD - Family Kid mover
W202 1998 C250D Factory OM605A Turbo - Partner's daily driver
W123 1982 300CD Retro fitted OM617A Turbo - Mine
W123 1984 300TD English 5 Speed Manual
W123 1982 300TD Factory OM617A Turbo (Hans) - Project
W123 1982 300D - OM617 NA (Hektor) - Son's
W123 1985 230TE - Brother's
W123 1985 300D - Sister in Law's
1962 S-Series Valiant (Tho Daimler & Chrysler divorced, still part of the extended family)
Past benzes
W114 1969 250CE - PO put in an M110 transplant and nearly sent me around the bend
W123 1981 300TD - "Matilda" - RIP hit front side & rear but left my brother + niece A-OK
Current Projects
Coupe restoration, Turbo Wagon freshen up
W202 1998 C250D Factory OM605A Turbo - Partner's daily driver
W123 1982 300CD Retro fitted OM617A Turbo - Mine
W123 1984 300TD English 5 Speed Manual
W123 1982 300TD Factory OM617A Turbo (Hans) - Project
W123 1982 300D - OM617 NA (Hektor) - Son's
W123 1985 230TE - Brother's
W123 1985 300D - Sister in Law's
1962 S-Series Valiant (Tho Daimler & Chrysler divorced, still part of the extended family)
Past benzes
W114 1969 250CE - PO put in an M110 transplant and nearly sent me around the bend
W123 1981 300TD - "Matilda" - RIP hit front side & rear but left my brother + niece A-OK
Current Projects
Coupe restoration, Turbo Wagon freshen up
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Re: Auto to manual transmission swap, a few questions.
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.
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Re: Auto to manual transmission swap, a few questions.
So, if it counts, today i put fresh oil in the diff and gearbox
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Re: Auto to manual transmission swap, a few questions.
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.
under the car, put in a welding rod to keep the shifter in neutral position to get all the nest parts done
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
in the vice
a quick snap shot of one of the tack welds before i go around and finish it up
all 3 welded, not the prettiest by a long shot, but nice and strong
painted with some paint that i had for a previous car that should keep the weather off them
greasing these up with moly grease, looks like they haven't been greased since factory
Next part is to make bushings for the shifter end
Here we have my 3d printer making them with some TPU flexible filament.
:)
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.
under the car, put in a welding rod to keep the shifter in neutral position to get all the nest parts done
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
in the vice
a quick snap shot of one of the tack welds before i go around and finish it up
all 3 welded, not the prettiest by a long shot, but nice and strong
painted with some paint that i had for a previous car that should keep the weather off them
greasing these up with moly grease, looks like they haven't been greased since factory
Next part is to make bushings for the shifter end
Here we have my 3d printer making them with some TPU flexible filament.
:)
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Re: Auto to manual transmission swap, a few questions.
rubber pieces in :) ( could redesign them to be a better fit, but at this stage as long as things work asap i'm happy
bonnet latch sucks with this home repair from previous owner...
replacement
all lubed up
it closes and opens so beautifully now
Fuel tank level sending unit....
a bit dirty... putting in new wire and cleaning it up
cleaned and reassembled
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 ;) )
bonnet latch sucks with this home repair from previous owner...
replacement
all lubed up
it closes and opens so beautifully now
Fuel tank level sending unit....
a bit dirty... putting in new wire and cleaning it up
cleaned and reassembled
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 ;) )
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Re: Auto to manual transmission swap, a few questions.
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.
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.
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- 170s
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Re: Auto to manual transmission swap, a few questions.
Well done congratulations :occasion5:
1989 560 SEL King of the road
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Re: Auto to manual transmission swap, a few questions.
Good Job.
What's the next project ? :occasion5:
What's the next project ? :occasion5:
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Re: Auto to manual transmission swap, a few questions.
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 :)
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Re: Auto to manual transmission swap, a few questions.
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Re: Auto to manual transmission swap, a few questions.
Signalrot :love4:
Current:
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124.051 716.62 Perlblau / Iceblau Gretel
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107.023 Astralsilber "Lurch" - now in the loving care of Craig B
201.035 Blauschwarz (parted) formerly owned by Derek/Hasan.
107.048 722.313 Signalrot Stella
124.051 716.62 Perlblau / Iceblau Gretel
201.034 717.404 Blauschwarz Hermann
212.074 722.931 Diamantweiß Klaus
124.090 722.358 Malachit Grün Beatrix
Previous:
126.039 Anthracitgrau "Schultz" - In Mercedes Heaven
201.029 Signalrot "Sabine" - has taken ownership of Andrew's Garage
107.023 Astralsilber "Lurch" - now in the loving care of Craig B
201.035 Blauschwarz (parted) formerly owned by Derek/Hasan.
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Re: Auto to manual transmission swap, a few questions.
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Re: Auto to manual transmission swap, a few questions.
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.
Current:
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Previous:
126.039 Anthracitgrau "Schultz" - In Mercedes Heaven
201.029 Signalrot "Sabine" - has taken ownership of Andrew's Garage
107.023 Astralsilber "Lurch" - now in the loving care of Craig B
201.035 Blauschwarz (parted) formerly owned by Derek/Hasan.
107.048 722.313 Signalrot Stella
124.051 716.62 Perlblau / Iceblau Gretel
201.034 717.404 Blauschwarz Hermann
212.074 722.931 Diamantweiß Klaus
124.090 722.358 Malachit Grün Beatrix
Previous:
126.039 Anthracitgrau "Schultz" - In Mercedes Heaven
201.029 Signalrot "Sabine" - has taken ownership of Andrew's Garage
107.023 Astralsilber "Lurch" - now in the loving care of Craig B
201.035 Blauschwarz (parted) formerly owned by Derek/Hasan.
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Re: Auto to manual transmission swap, a few questions.
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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Re: Auto to manual transmission swap, a few questions.
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.
Life is a journey, with problems to solve, lessons to learn, but most of all, experiences to enjoy.
'83 W123 300D 325000km (Wife's car Josephine - sold).
'84 W123 300D replaced good OM617 912 with OM617 952 and enjoyed having good acceleration for the first time since first driving a 300D in 2002
'86 W124 300D sold
'85 W123 300CD, 275 000km (Fatmobile) rebuilt turbodiesel transplanted into 280CE (SOLD)
'99 W202 C250 Turbodiesel
'98 W202 C250 Turbodiesel
'06 Ssanyong Musso Crew Cab 2WD Ute (OM662 diesel and Auto Transmission)
'00 Ford Courier Crew Cab 2.5TD
'06 Ssanyong Musso Crew Cab 4WD Ute (OM662 diesel and Auto Transmission)
'04 Ssanyong Musso Crew Cab 4WD Tray back Ute (OM662 diesel and Auto Transmission)
'83 W123 300D 325000km (Wife's car Josephine - sold).
'84 W123 300D replaced good OM617 912 with OM617 952 and enjoyed having good acceleration for the first time since first driving a 300D in 2002
'86 W124 300D sold
'85 W123 300CD, 275 000km (Fatmobile) rebuilt turbodiesel transplanted into 280CE (SOLD)
'99 W202 C250 Turbodiesel
'98 W202 C250 Turbodiesel
'06 Ssanyong Musso Crew Cab 2WD Ute (OM662 diesel and Auto Transmission)
'00 Ford Courier Crew Cab 2.5TD
'06 Ssanyong Musso Crew Cab 4WD Ute (OM662 diesel and Auto Transmission)
'04 Ssanyong Musso Crew Cab 4WD Tray back Ute (OM662 diesel and Auto Transmission)
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- Dernburg Wagon
- Posts: 9
- Joined: Mon 08 Jan, 2018 4:03 pm
- Model you own: w123
Re: Auto to manual transmission swap, a few questions.
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.
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- Große
- Posts: 1005
- Joined: Sun 08 Jun, 2014 6:03 am
- Model you own: w123
- Location: Brisbane, North side.
Re: Auto to manual transmission swap, a few questions.
Glad this thread has been useful :)
Where abouts are you located ?
I've moved house and haven't set up my 3d printer yet.
Where abouts are you located ?
I've moved house and haven't set up my 3d printer yet.
- julian
- M-100
- Posts: 687
- Joined: Thu 16 Jun, 2011 10:53 am
- Model you own: w126
- Location: Back in Adelaide.
Re: Auto to manual transmission swap, a few questions.
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.
300TD
250SE
20 year old Subaru Outback that will not quit
Peugeot 508 wagon
Previously: 1977 300D, 1979 300TD, 1982 280SE, 1988 560SEL, w123 Lang
250SE
20 year old Subaru Outback that will not quit
Peugeot 508 wagon
Previously: 1977 300D, 1979 300TD, 1982 280SE, 1988 560SEL, w123 Lang
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- Große
- Posts: 1005
- Joined: Sun 08 Jun, 2014 6:03 am
- Model you own: w123
- Location: Brisbane, North side.
Re: Auto to manual transmission swap, a few questions.
:)
happy to help
happy to help