Converting my 94 C220 from Auto to Manual 5speed - Mercedes-Benz Forum
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post #1 of 31 (permalink) Old 04-24-2011, 10:41 PM Thread Starter
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Vehicle: 1983 Mercedes 300DT 301500 miles
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Converting my 94 C220 from Auto to Manual 5speed

Converting my 94 C220 with 249 000 miles from Auto to 5 Manual. Here is what I have done and found out so far:

1.A manual transmission out of a 190E or 190D will fit. It can be the 5 speed 717.411 or the close ratio 5speed getrag with dog leg first gear.
2. Pedal assembly from the 190E 190D will fit with small modifications in order to connect the top bolt on the bracket.
3. The Shifter from 190E/190D will fit (it has to be for the corresponding transmission - can't use the getrag shifter with dog leg first on the 717.411)

Now for the problematic parts:
1. Flywheel. The one that I got out of a 87 190D is the so called single mass. It bolts on but does not have the timing magnet and the two triggers. So the car won't fire with that one unless it is modified with the two triggers and magnet transferred from the flexplate to the flywheel.
I tried doing that with no luck. It is probably possible if done by a shop.
I ended up ordering a flywheel from a 95 C180 from germany. Just ordered that today.
2. The driveshaft will have to be longer since the manual transmission is shorter then the automatic by 11cm. I did take the driveshaft from the 190D but it won't fit. The idea was to keep the rear part of the c220 drive shaft and use the front part of the 190d drive shaft.
The problem is that the 190D rear drive shaft it shorter then the c220 rear part (basically the carrier bearing is located further toward the front in the c220). This makes the front part of the 190d drive shaft too long. It seems to be too long by approximately 9cm. This brings the idea that if I get the front part of the drive shaft off of 190e with auto transmission it will be just the right length. I will be going to the junkyard next saturday to give it a try.
3. The transmission crossmember from the 190D will not bolt up to the C220. I have not found any possible solutions for this problem yet. I will either have to modify the crossmember from the 190D and make it fit or I will try using a crossmember out of a w123 240d manual (there is one in the junkyard).
4. The bracket that holds the exhaust to the transmission will have to be modified.
5. I don't know if the shifter linkage will be the right length or if I will have to modify those.

And here is the pictures so far:
All the parts came out of a 1987 190D 2.5 with about 220k miles. It is obvious why the car ended up in the junkyard - the pressure plate of the clutch had broken fingers and the throw out bearing was destroyed. Had to use an angle grinder to remove it.
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1983 Mercedes 300D Turbo 327 000 miles. Spare car.

1994 Mercedes C220 converted to run on Natural gas.
Bought at 138 200 miles, current odometer: 310 500 mi
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post #2 of 31 (permalink) Old 04-24-2011, 10:58 PM Thread Starter
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there was some metal shavings on the magnet. Hopefully the transmission is good. The oil was nasty and probably the original oil but at least it was not low.
Flushed it twice and put in some valvoline dex III oil.
Cleaned the transmission some more and replaced the clutch slave cylinder with a new one. The old one pretty much fell apart when I took it out and also the tip of it was worn out from pushing. Greased all the joints (according to the manual).
Spray painted the shifter linkage.
Recieved the new clutch its Sachs (by the way the clutch plate and pressure plate in the 190d were sachs original stamped 1986 and the clutch plate was not even all that worn out. I can make pictures if you guys wonder what it looks like after 220k miles).
The clutch kit was a really good deal. Got it from autopartsnetwork for $174 with free shipping. Part number KF297-02. It came with the clutch disk, pressure plate, throw out bearing and clutch alignment tool. This clutch kit is for transmissions with single mass flywheel. I also installed the carrier bearing in the back of the crankshaft (ordered one for 87 190E) it fits just right and yes there is an opening in the back of the crankshaft. I will take pictures of it. If there wasn't then you can always use a dual mass flywheel which has the carrier bearing integrated into it.
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Jacques405 likes this.

1983 Mercedes 300D Turbo 327 000 miles. Spare car.

1994 Mercedes C220 converted to run on Natural gas.
Bought at 138 200 miles, current odometer: 310 500 mi
Tedd300DT is offline  
post #3 of 31 (permalink) Old 04-24-2011, 11:01 PM
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I knew there was a reason to stay up till 2am... a manual W202 conversion, the first i have ever seen stateside, please keep us updated. Great job so far!!!

Kinda pissed now that I have ordered a driveshaft from Driveline of Portland. could have waited to see the parts list for this conversion and spent the money on it.

Oh well, on the bright side, my new driveshaft will hold me until your projct is completed
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post #4 of 31 (permalink) Old 04-24-2011, 11:12 PM
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Nice start, keep the board posted on your progress. I'm sure you researched using the R170 as a doner for this project. Finding one or the parts can be pricey. Any idea what you think the final cost will be? I never thought as the 201 as a doner.
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post #5 of 31 (permalink) Old 04-24-2011, 11:13 PM Thread Starter
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comparing the flexplate to the flywheel. I marked it and moved the timing plates to the flywheel. Epoxied them for testing. Got the car running but it was always scraping in to something and woudn't start easy. Tried it a few times and gave up and ordered the flywheel from germany.
Removed the center console and automatic shifter. Installed the manual shifter and ran a cable from the reverse light switch on the manual shifter to the connector of the auto transmission and wired the lights. Also while there I bypassed the neutral safety switch (you could wire it through the clutch so that it won't let you turn the starter when the clutch is not depressed) but I didn't want to do that. There is a total of 6 wires on the auto connector. Two (thick ones) are the neutral safety, two are the reverse lights and I have no idea what the other two are. I have left those alone for now.
I also had the carpet removed and after i Installed the pedals I ran the supply hose up to the brake reservoir and the routed the line from the master cylinder out to the transmission. Modified the kick panel. Also wired the brake lights switch. NOTE I have not wired the switch on the clutch pedal yet. This will have to be wired so that it would disengage the cruise control.
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1983 Mercedes 300D Turbo 327 000 miles. Spare car.

1994 Mercedes C220 converted to run on Natural gas.
Bought at 138 200 miles, current odometer: 310 500 mi
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post #6 of 31 (permalink) Old 04-24-2011, 11:21 PM Thread Starter
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here is a picture of the drive shafts
top of the picture is the rear part from 190d
2nd from top is rear part from c220 (by the way my center support was completely shot - not surprised it is probably original with 250k miles).
3rd from top is front part from 190D manual
4 from top is front part from c220 auto

I haven't taken pictures of the installed shifter yet. Will post those when I do. I will be waiting until next saturday to go to the junkyard and see if I can get the front drive shaft out of 190e automatic and see if that would fit. And ofcourse will be waiting on the flywheel from germany which is probably going to take a while. Anyway if anybody has done this before please give ideas on the current issues - driveshaft, crossmember and possibly shifter linkage.
Thanks.
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1983 Mercedes 300D Turbo 327 000 miles. Spare car.

1994 Mercedes C220 converted to run on Natural gas.
Bought at 138 200 miles, current odometer: 310 500 mi
Tedd300DT is offline  
post #7 of 31 (permalink) Old 04-24-2011, 11:28 PM Thread Starter
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the r170 seems to be very expensive to find. So Far I have spent $200 in the junkyard - that's for the transmission, flywheel, clutch disk, pressure plate (bad), linkage, shifter, pedals, master and slave cylinder, lines between master and slave. $175 on the clutch kit and another $35 on the slave cylinder and transmission carrier bearing. And just spent $110 on the flywheel from germany which half of that was for shipping with DHL.
so total is $520. I am way over budget. I was hoping to get this done with $250 and use the old clutch for starters oh well. I will be selling the flywheel I have and some other left over parts to make up for the cost.
Decided to go with the manual from 190e because I know the auto from 190e fits my c220 (done that one before) so i figured the manual will bolt on as well and they seem to be not impossible to find.

1983 Mercedes 300D Turbo 327 000 miles. Spare car.

1994 Mercedes C220 converted to run on Natural gas.
Bought at 138 200 miles, current odometer: 310 500 mi

Last edited by Tedd300DT; 04-24-2011 at 11:31 PM.
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post #8 of 31 (permalink) Old 05-01-2011, 12:26 AM Thread Starter
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Here is a picture of the shifter installed. I need to get a new leather boot for it. I am still waiting on the flywheel to arrive. I did get the front piece of the drive shaft of a 190e automatic and according to my calculations it will fit.
I will update again when I get the flywheel and start putting it back together.
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1983 Mercedes 300D Turbo 327 000 miles. Spare car.

1994 Mercedes C220 converted to run on Natural gas.
Bought at 138 200 miles, current odometer: 310 500 mi
Tedd300DT is offline  
post #9 of 31 (permalink) Old 05-01-2011, 07:53 AM
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Awesome! I wish I could do this to my car... or better, if it was originally stock manual.
Just wondering, what prompted you to make the conversion now?
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post #10 of 31 (permalink) Old 05-05-2011, 04:54 PM Thread Starter
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I always wanted to have this car with a manual but since it wasn't offered as manual in USA I decided to convert it. The automatic is ok but it is never in the right gear (unless you are doing 80mph on the freeway - upshifts when I don't want it to or doesn't downshift when I want it to. And me shifting it manually bothers me. But other then that you always have one free hand
Oh yeah and the manual 5 speed is overdrive at 1:0.78. So no more 3500rpm at 80 Mph - I hope
Will see how the manual turns out. Still waiting on the flywheel. I found out that a flywheel from 87, 88 or 89 190e 2.3 should have the two timing segments and in that case only the magnet would have to be added which is easy. I also found out that the cross member from the 190e manual doesn't fit at all but with a lot of grinding and drilling I made it fit (I think) . I am still not sure if the driveshaft out of the 190e automatic will fit ok, the 190e manual driveshaft is too long for sure. I did replace the carrier bearing and rubber because it was shot. I will post an update again as soon as I get the flywheel.

1983 Mercedes 300D Turbo 327 000 miles. Spare car.

1994 Mercedes C220 converted to run on Natural gas.
Bought at 138 200 miles, current odometer: 310 500 mi
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