w202 - getrag conversion

Discussion in 'Engine' started by c280turbo, Sep 20, 2011.

  1. c280turbo

    c280turbo Member

    Messages:
    48
    Joined:
    Sep 20, 2011
    Car:
    1999 C43
    i am currently in the process of turbo charging my c280 m104 engine (5 speed manual)

    and wondering what is involved in fitting the 190 cosworth cosworth gearbox??

    i ve found out it bolts straight up and i can use the exisiting m104 flywheel

    do i need the cosworth clutch kit??

    what about prop ??
    slave cylinder??
     
  2. Druk

    Druk Administrator Staff Member

    Messages:
    5,309
    Joined:
    May 28, 2004
    Location:
    Not far from Edinburgh.
    Car:
    2011 S212 E350CDi. 1981 R107 300TurboDiesel.
    I have both gearboxes in the garage (from a W124). Presuming your car has the dual mass flywheel it will be OK cos the Getrag box has a shorter first motion shaft than a box which uses a single mass flywheel. My Getrag also has a different arrangement of the change levers and it's own corresponding gear turret. The output flange on the Getrag is slightly bigger but the shaft is the same length iirc. Other than that they look the same.

    Welcome to the forum BTW.
     
    Last edited: Sep 20, 2011
  3. OP
    OP
    c280turbo

    c280turbo Member

    Messages:
    48
    Joined:
    Sep 20, 2011
    Car:
    1999 C43
    yes my w202 has the dual mass flywheel, so would the c280 clutch work or would i need the 190 clutch??

    prop would be the 190 also?
     
  4. Druk

    Druk Administrator Staff Member

    Messages:
    5,309
    Joined:
    May 28, 2004
    Location:
    Not far from Edinburgh.
    Car:
    2011 S212 E350CDi. 1981 R107 300TurboDiesel.
    I don't know what will work on your car. I'm saying what the differences are between the standard box and the Getrag I have. If you already have the dual mass then that should be OK but you'll need to measure and compare the length of the input shafts of the two boxes to see if they match. The two output flanges are different sizes on my boxes though so another thing to be checked, however both my boxes are from w124's so things may have changed with the 202. What I think will be different is the turret cos the Getrag has the 1st gear as a push action on the change rods whereas the standard box is a pull. My two turrets are totally different as are the rod lengths but the four bolt centers are the same so they are interchangeable.

    Another thing I've just thought of...you are aware that the Getrag box has a direct drive top gear so you will probably have to change the diff as well or you'll be revving it's head off at any decent speed?



    .
     
    Last edited: Sep 20, 2011
  5. BlackC55

    BlackC55 Authorised Forum Sponsor Authorised Forum Sponsor

    Messages:
    18,745
    Joined:
    Feb 8, 2007
    Location:
    Horndean, Portsmouth, Hampshire, Southsea
    Car:
    C43 AMG with a 55 engine and supercharger, E55 AMG, S500, etc
    Just one question. Why are you considering it?
     
  6. OP
    OP
    c280turbo

    c280turbo Member

    Messages:
    48
    Joined:
    Sep 20, 2011
    Car:
    1999 C43
    because my current box will not cope with 400bhp
     
  7. OP
    OP
    c280turbo

    c280turbo Member

    Messages:
    48
    Joined:
    Sep 20, 2011
    Car:
    1999 C43

    thankyou for the info :)
     
  8. carat 3.6

    carat 3.6 Hardcore MB Enthusiast

    Messages:
    3,923
    Joined:
    May 11, 2011
    Location:
    Buckinghamshire, yuppie central 1985.
    Car:
    96 e300d, 88 w124 superturbodiesel, 90 bmw E30 v8, + "others"
    The daulmass flywheels and any of the standard clutches will not handle 400hp for very long, you need to use the old single mass flywheel from the m103 along with a clutch kit from black diamond.

    You can get a getrag with both long and short input shafts, so make sure you get the short version.

    The cosworth slave cylinder will be fine. You may need to change the front section of the propshaft for a different length, work out what length you need and call "mercman of cornwall" they will sort you out with that.

    You will also need to alter the flexable rubber couplings in the propshaft, and fit solid ones insted. I think "nick.ged" has done this already.

    What system are you going to use to control it all?
     
  9. d w124

    d w124 MB Club Veteran

    Messages:
    12,346
    Joined:
    Dec 30, 2008
    Location:
    london
    Car:
    w124 3.6AMG styling E320 S124 Lorinser styling
    To achive over 200 bhp on a single turbo is impresive,please tell us more
     
  10. OP
    OP
    c280turbo

    c280turbo Member

    Messages:
    48
    Joined:
    Sep 20, 2011
    Car:
    1999 C43
    its going on dta s60

    custom made ttv single mass flywheel and clutch from spec in usa will see that side of things sorted

    i am going to use a gt3582r with external wastegate
    custom exhaust manifold
    3" exhaust system
    190 cosworth rear lsd
    60lb injectors
    bosch 044 fuel pump
    arp head studs
    ferriday engineering decompression plate
    r&r custom h section steel rods
    big intercooler
    and alot of boost :bannana::bannana:
     
    2 people like this.
  11. BlackC55

    BlackC55 Authorised Forum Sponsor Authorised Forum Sponsor

    Messages:
    18,745
    Joined:
    Feb 8, 2007
    Location:
    Horndean, Portsmouth, Hampshire, Southsea
    Car:
    C43 AMG with a 55 engine and supercharger, E55 AMG, S500, etc
    I dont think you will have much of an issue with the gearbox. They are very strong and rarely go wrong. You may have to change the ratio's though.

    Good luck with the project it sounds awesome.
     
  12. NW_Merc

    NW_Merc Banned

    Messages:
    5,918
    Joined:
    Sep 3, 2005
    Location:
    Over here, sometimes over there
    Car:
    1994 Mercedes C180 classic

    Who made the intercooler for you, I'm assuming it is front mount beneath the bumper?
     
  13. OP
    OP
    c280turbo

    c280turbo Member

    Messages:
    48
    Joined:
    Sep 20, 2011
    Car:
    1999 C43
    its just an ebay style intercooler
     
  14. OP
    OP
    c280turbo

    c280turbo Member

    Messages:
    48
    Joined:
    Sep 20, 2011
    Car:
    1999 C43

    what gearbox do you mean the std w202 5 speed or the 190 cosworth 5 speed ??
     
  15. BlackC55

    BlackC55 Authorised Forum Sponsor Authorised Forum Sponsor

    Messages:
    18,745
    Joined:
    Feb 8, 2007
    Location:
    Horndean, Portsmouth, Hampshire, Southsea
    Car:
    C43 AMG with a 55 engine and supercharger, E55 AMG, S500, etc
    Yes the standard 5 speed
     
  16. OP
    OP
    c280turbo

    c280turbo Member

    Messages:
    48
    Joined:
    Sep 20, 2011
    Car:
    1999 C43
    ok cheers i will see how it goes then

    motor and gearbox only done 60k so are in excellent condition, fingerscrossed it holds together will save me a few quid

    i could always get the gearset shot peened for added strength:thumb::thumb::thumb:
     
  17. carat 3.6

    carat 3.6 Hardcore MB Enthusiast

    Messages:
    3,923
    Joined:
    May 11, 2011
    Location:
    Buckinghamshire, yuppie central 1985.
    Car:
    96 e300d, 88 w124 superturbodiesel, 90 bmw E30 v8, + "others"
    If you do go with custom conrods, just have them made 2 - 3mm shorter so you wont need the de-compression plate.
     
  18. OP
    OP
    c280turbo

    c280turbo Member

    Messages:
    48
    Joined:
    Sep 20, 2011
    Car:
    1999 C43
    the decompression plate is the 1st stageof the build this will see me install all the ancillaries to get the conversion on the road and to iron out any issues, once i am satisfied i will then take the engine out and have the rods fitted, along with having the head worked on and maybe if funds allow a slight tweak to the cams ( a regrind)
     
  19. BlackC55

    BlackC55 Authorised Forum Sponsor Authorised Forum Sponsor

    Messages:
    18,745
    Joined:
    Feb 8, 2007
    Location:
    Horndean, Portsmouth, Hampshire, Southsea
    Car:
    C43 AMG with a 55 engine and supercharger, E55 AMG, S500, etc
    I have a LSD from a C63 that you could use.
     
  20. NW_Merc

    NW_Merc Banned

    Messages:
    5,918
    Joined:
    Sep 3, 2005
    Location:
    Over here, sometimes over there
    Car:
    1994 Mercedes C180 classic
    Would that slot into a W202? :dk:
     

Share This Page

  1. This site uses cookies to help personalise content, tailor your experience and to keep you logged in if you register.
    By continuing to use this site, you are consenting to our use of cookies.