w124 om606 auto to manual swap

[carat 3.6]

Ok guys, following on from the http://www.mbclub.co.uk/forums/engine/121683-w124-0m606-flywheel-sensor.html thread, today I set about the gearbox swap. It's not finished yet but hopefully will be driving again by tomorrow night.

Progress so far today has been the removal of the autobox, tourqe converter, and flex plate, and the fitting of the manual box, clutch and flywheel. I also swaped the gear levers and linkage, but due to the donor parts being from a 190e the rods needed extending by 1" to reach the gearlever.

The front half of the propshaft needed to be changed for a longer item, but I didnt have one! So I ended up using the front half from a 560sel, with the flange from the original propshaft welded in place of the v8 one. We will see how well that holds up tomorrow.

The flywheel and clutch used is a solid state unit from a m111, and due to it being alot lighter than the tourqe converter or the daulmass flywheel the car should have, it now revs noticbly easier.

I'll post an update on progress tomorrow.

 

[carat 3.6]

A couple of pics....

 

[krimat2005]

just be carefull with propshaft, as you're using 2 halfs from 2 difrent cars because they're balanced one to another. if you get vibrations you need to get whole prop from one car that will fit, unless you can get this one balanced.

 

[carat 3.6]

Todays update.

The modified propshaft and gearbox crossmember are both fitted, and the old oil lines to the gearbox cooler in the radiator have been removed.

I made up a clutch fluid line from copper 3/16 brake pipe, and 2 unions. This fitted well but upon trying to bleed the clutch, I discovered the slave cylinder is leaking. New one being delivered tomorrow morning....

I also re-routed the wiring for the autobox, starting from it's multi-plug in the passenger footwell. There are 4 wires, 2 purple, 1 red and black, and 1 that I cant remember. The 2 purples are for the starter inhibitor switch, which I just joined together. The other 2 are for the reversing light switch, which were made longer and wired to the new switch at the base of the gearlever.

The kickdown cable has been removed, and the vacum pipe for the gearbox followed back and disconnected.

As soon as the replacement slave cylinder is on, I'll take it for a test run.

More tomorrow...

 

[carat 3.6]

More pics...

 

[carat 3.6]

Finaly got the new slave cylinder today, fitted that and took the car for a test run. (That is after I fitted the gear linkage rods the corect way, instead of having reverse where 4th should be )

What a diference! The car is now alot more eager to get away from junctions and climb hills, no more slugish auto. Seems to be quite rev happy with the m111 flywheel, but dosent lose much speed up the hills either.

The cut-n-shut propshaft dosent seem to be making any vibration, so I'll leave that alone for now. Next job is to get the correct gaitor and gearknob, mine needs a lift up reverse.

Intrestingly the gearbox that I used (714.435 from a 190e 2.6), has the same gear ratio's as the auto that came out. The only diference being that I now have an extra gear to play with.

I'll keep you all posted on any updates.

 

[Dieselman]

A great mod, well done.
The flywheel won't make any difference once driving, the heavier mass is for idle smoothness.

 

[carat 3.6]

If anyone is intrested in the old auto gearbox, tourqe converter, flywheel, ect, please send me a pm.

Nothing wrong with it, but has covered 233k.