Mercedes W123 Manual Gearbox Problems

Mercedes W123 Manual Gearbox Problems Average ratng: 7,6/10 1530 reviews

1982 Mercedes-Benz 280CE W123. Manual TransmissionMercedes-Benz 280CE. With extremely rare 4-speed manual transmission. Other rare specification includes: No rear seat belts.

No n/s door mirror. No rear head rests. Manual windows. Straight-grain walnut trim.

I've been reading and looking at the Mercedes Benz 240D W123 series. Lists the pros and cons of the manual and automatic transmission in the 240D. The only issue with the automatics is if you dont understand them.

Fire extinguisher. Centre arm rest. Alloy wheels. Electric sunroof. Green tinted glass with heated rear window.

Headlamp wash / wipe. Limited-slip differential and paintwork code 940 Hansa Blue. Mileage is currently 104700. This stunning CE has been in dry storage for ten years and has just received a full and detailed re-commission in our workshops including new clutch assembly. New Pirelli tyres. Major service and complete waxoil treatment. Condition is exemplary throughout and the manual gearbox makes this a real drivers car with surprising economy.

The car comes with steel wheels with painted trims and fully re-furbished original alloys with the afore-mentioned Pirellis. We are happy to provide a full warranty and may possibly take a part-exchange. This is a unique opportunity to acquire undoubtedly one of the rarest specification 280CEs in existence in truly outstanding condition.Please contact Martyn or Susie Marrocco on 09 / 44Also published at eBay.co.uk Want to buy this car?

(, 10:47 AM)vstefis Wrote: Best bet would be a stock 5-speed trans for the w123 (any engine). The side levers are pretty much the same as the ones in the 4-speed manual, except a bit shorter. Anywho, easily modifiable via the cut and weld method.

The gearstick thingy is different, you'd need that, plus the short driveshaft bit, cross member, and that's about it.Easy to do, so I'd look for this. Plus it's original. And pretty good as well.Thanks for the tips,BUTHave been looking off and on for over 6 months and no joy.That's why the thoughts to convert to a more readily available Mercedes 5 or even 6 speed.Are these stock 5-speeds you mention available in your 'neck of the woods'???If so, there are 3 of us in the area looking for a 5 speed that will bolt up to the OM617.All 3 of us have 300TD wagons (estates) and one of the guys has been looking longer than I have and only found 4 speed manuals,NO 5 speeds located to date.Robert. (, 02:17 PM)vstefis Wrote: I can only say good things happen to those who wait.Perhaps, but for those of us who care to take an approach different from looking and waiting.and still explore the distinct possibility of building an adapter and using it to install a Mercedes 5 speed manual from a vehicle that is readily available and common enough to be inexpensive and easily fit.The search continues, perhaps someone else will lend some answers to the questions asked in this thread.Thanks,Robert. (, 04:55 PM)aaa Wrote:Thanks for the URL to the excellent thread.It is full of useful information that shows very good work.The approach taken, while extraordinary in my opinion, is much more difficult to repeat when compared to manufacturing your own adapter and flywheel.The thread showed the transmission adapted to the engine, but with an adapter and custom flywheel, it will be the other way around. This will eliminate any changes to the housing and first motion shaft.

Am not knocking the good work, just would take a different approach.This was exactly the sort of information I was searching for.It showed that other Mercedes transmissions had already been adapted and will work just fine provided you have the donor shifter that matches the adapted transmission and make the other changes in linkage, mounting, driveshaft sizing, and so on.My approach will be to find a plentiful 5 speed form the 80s early 90s era and make an adapter and flywheel so that the transmission won't need any modifications. Then if the adapted transmission fails or needs a rebuild it can be exchanged for another unit. Also the clutch will match the transmission shaft splines and length.Still need to research the spedo gear ratio on the donor unit and ensure an accurate reading. Hopefully this will lead me to purchase a unit to start the project.On another note, there was a 6 cyl Mercedes gas 250 engine and transmission that came out of a 1985 W124 on UK ebay.

The seller wasn't sure if it was a 4 or 5 speed, but the shape of the back of the housing may identify this or wonder if part numbers or markings somewhere on the housing would identify the number of gears. Would think there must be lists somewhere that specify this if you know the right numbers. Any suggestions here?Robert.

W123 Getrag 5 speeds are 717.400. If you find a car with it in the states they are most likely from 1981+ Euro 280E/CE/TE, 300D/CD/TD and 240D.I found one in a 1982 280CE and took all the related parts.The G-Wagon 280GE and 300GD had the Getrag 717.420 trans which is the same as the 717.400.Here is one for sale on ebay.de.If you are going to use a trans with the starter on the opposite side, you'll need to relocate the oil filter housing.Here is a thread of this discussion. It looks like some the pictures are gone though. (, 08:02 PM)DeliveryValve Wrote: w123 Getrag 5 speeds are 717.400.

If you find a car with it in the states they are most likely from 1981+ Euro 280E/CE/TE, 300D/CD/TD and 240D.I found one in a 1982 280CE and took all the related parts.The G-Wagon 280GE and 300GD had the Getrag 717.420 trans which is the same as the 717.400.Here is one for sale on ebay.deIf you are going to use a trans with the starter on the opposite side, you'll need to relocate the oil filter housing.Here is a thread of this discussion. It looks like some the pictures are gone though.Good to know, thanks.Regarding the oil filter housing:For the Land Rover OM617 conversion, we are making an adapter to take the Land Rover 300 TDI oil Filter housing which points a spin-on oil filter downward and out of the way of the bulkhead and still has internal thermostats that regulate the oil flow through the oil cooler. (, 05:44 AM)aaa Wrote: The 124 250D transmission would be just like a 190D's transmission, same starter hump issue.Sorry fat fingered the keyboard and after only 1 beer.It is a manual transmission attached to a gasoline straight 6 cylinder 250 engine from a 1985 W123 not W124. Assume this engine is externally the same as the 2.8 liter straight 6, but with smaller displacement.Heard back from the seller and the shift linkage and petal assembly were already removed from the vehicle, but the vin is: WDB5443Will this help identify the number of gears if it still had the original manual transmission?

I'll send him the question regarding the 717.4xx and share the answer.Robert. (, 09:45 PM)sassparillakid Wrote: Can we just have somebody with a lot of time on their hands manufacture a bunch of these 5 speeds so its not like a quest for the Holy Grail to get one? LolThat was the original intent.Because the aluminum casting that mounts to the back of the OM617 engine block determines the starter location and matches the transmission bolt pattern, it can be removed and a newly machined 'flywheel housing & transmission adapter' mounted in it's place. This new adapter would then match the 'donor 5 speed manual transmission' (that originally matched a different Mercedes engine with the starter on the left) along with a custom made flywheel that takes the donor clutch (so there are no changes to the transmission shaft) and spaces the clutch out the same distance as the donor.

This custom flywheel bolts to the OM617 crankshaft and takes the donor ring gear so the donor starter bolts to the custom adapter and starts the OM617 engine. (had to read that one twice to make sure it was typed correctly)Then we make a batch of these and buy 1 or 10 suitable donor transmissions in Europe along with the proper shifter (cheaply) and ladies and gentlemen, we have a 5 speed conversion (after you relocate the oil filter, complete the linkage, come up with a transmission mount, and complete any required driveshaft work).In theory a great idea. In practice a lot of trouble if the holy grail of a 5 speed shows up on eBay UK or eBay DE at a reasonable price of $500 or less, then we might not take 'the road less traveled, Robert Frost -er ah sassparillakid' and forget the conversion.Robert. (, 05:50 PM)sassparillakid Wrote: Oh ok yeah I forgot about the starter. So where does the oil filter housing get relocated to?You probably didn't see it in post 9 as follows:Regarding the oil filter housing:For the Land Rover OM617 conversion, we are making an adapter to take the Land Rover 300 TDI oil Filter housing which points a spin-on oil filter downward and out of the way of the bulkhead and still has internal thermostats that regulate the oil flow through the oil cooler. This may be a candidate to replace the original filter housing. (, 01:51 AM)sassparillakid Wrote: I might be interested.

Also, the expense was going to be gone through to cast new bellhousings, why not just just cast new ones for mercedes transmissions that that may/may not require as much work to adapt transmission mounts, driveshafts, etc.? Is there any reason other than scarcity of these as opposed to the chevys?Very good question.I could be wrong, but was under the impression that 99% of the available Mercedes manual 5 speed transmissions were one piece main castings without a removable belhousing. I think if these later 5 speeds with the starter on the left side had a removable belhousing, someone else probably would have made such a belhousing adapter long ago. That's my thinking and with the Mercedes I am still a student of learning so again could be wrong.Perhaps someone with more knowledge than we currently have could verify.The T-5, manufactured by Borg Warner, used in Chevy's, Fords, and lots of other marques is cheap and available right here in our USA junkyards. Parts are everywhere and most re-builders have them exchange or outright.After talking to a local 300TD owner who has been looking for a year and my own 6 month search, the only suitable Mercedes 5 speeds, that I saw were for G-Wagons and wouldn't have found those if it hadn't been for the guidance from DeliveryValve who turned me on to the 717.420.

You'd probably have several thousand in a complete kit if you sourced a 717.420 in Germany or the UK and then you'd still have to locate a 5 speed shifter and make the rod mods along with the driveshaft and rear mount changes seen on some of the conversion links.So am going to look into the costs associated with casting a belhousing for the BW T-5 if more detailed measurements prove it is possible.Robert. Re: starter relocation: you could also use a /8 240D 3.0 block with the oil filter housing up front.But these came only in the 80HP fashion and have a different bore to the 88HP engines and thus would require a re-bore & 88HP oversize pistons. Or modified pistons to clear the 88HP pre-chambers - and so on.

There's no easy way unless you wait for that Getrag 717.400. And then's the question - how worn out is it?

Does it need a rebuild? I found mine in France, for 250€ - the whole convesion kit sans gearbox bracket (auto bracket should work too). Luckily with only 105k miles on the odomater.With the later 190 or W124 transmissions you'd need a custom made or shortened and rebalanced drive shaft, as they'r a bit shorter than the 717.400/401 - yet the 717.400/401 is shorter than the W123 auto box.W123 4spd W124/190 5spd W123 5spd W123 autoI too had plans to have a custom adaptor plate made - but machining would've been expensive (it's not just a simple plate, it needs to be recessed to make room for the flywheel - there's a lot of machine time involved.

Unless a smal batch of about 10-20 is made, it's too expensive. Renault megane scenic owners manual 2003. At least in my country. (, 12:52 PM)808morgan Wrote: Try this:Thanks for the link.They have everything, but the only drawback is the transmission is a 4-speed.

Would like to make the change to a 5-speed.Robert(, 06:17 AM)DiseaselWeasel Wrote: Re: starter relocation: you could also use a /8 240D 3.0 block with the oil filter housing up front.But these came only in the 80HP fashion and have a different bore to the 88HP engines and thus would require a re-bore & 88HP oversize pistons. Or modified pistons to clear the 88HP pre-chambers - and so on. There's no easy way unless you wait for that Getrag 717.400. And then's the question - how worn out is it? Does it need a rebuild?

I found mine in France, for 250€ - the whole convesion kit sans gearbox bracket (auto bracket should work too). Luckily with only 105k miles on the odomater.With the later 190 or W124 transmissions you'd need a custom made or shortened and rebalanced drive shaft, as they'r a bit shorter than the 717.400/401 - yet the 717.400/401 is shorter than the W123 auto box.W123 4spd W124/190 5spd W123 5spd W123 autoI too had plans to have a custom adaptor plate made - but machining would've been expensive (it's not just a simple plate, it needs to be recessed to make room for the flywheel - there's a lot of machine time involved.

Unless a smal batch of about 10-20 is made, it's too expensive. At least in my country.Thanks for the pictures and interesting info. Had no idea there was a OM617 with oil filter that far forward.Robert. Old thread but is the only one I found that have some information regarding the subject I want to ask:I want to do the opposite of the tittle of this thread, I have an W115 240d 3.0 with the OM617 80hp with 4 spd manual gear box and I want to convert it to W115/w123 auto gear box, but my big question is, which flywheel to use??In EPC the W115 w240d 3.0 have an unique flywheel part number, but the outer ring is the same as in other models, and in pictures all look the same!What are the differences and from witch models can I use the flywheel?Thanks.