[Brian McL]

I have a 2003 C240 with the 6 speed manual tranny and it is very difficult to get it into 1st / 2nd. No grinding just doesn't want to go in at a stop. If I go up through all the gears then try 1st again it will go in..70% of the time....but not without some force.
Clutch seems fine and all the other gears are also fine. Can't see the linkage very well, looking for bushings, what I could see looked fine.
Any ideas?
Also, if the tranny needs to be R&R'd does anyone have a link to a service manual that lays out the procedure?
Thanks

 

[300DFan]

That sounds like the clutch isn't completely disengaging. It could be something simple like a hydraulic problem - low fluid or slowly failing master cylinder. Or it could be something inside the bell housing.

This happened to my son's BMW last year and it turned out to be a cracked pressure plate. But check the hydraulics first.

Does it shift properly with the engine off?

 

[Brian McL]

Shifter

I'll check it tomorrow to see if it shifts with the engine off. If it is the same as with the engine running what does that indicate? Thanks for the reply.

 

[Patch's]

Try double clutching, see if that make any difference?

Also note if you feel any drag at all when engaged in first, or if the rpm slows after engaging?
The first place I would start is as 330D said. The old systems can get clogged, a complete flush may help providing you keep air out of the system.
A hand held vacuum pump works well for this. I personally use dot 3

Patch

 

[300DFan]

I'll check it tomorrow to see if it shifts with the engine off. If it is the same as with the engine running what does that indicate? Thanks for the reply.

If it's the same when the engine isn't running it's not caused by a dragging clutch. It would be an issue with the linkage or possibly within the transmission. If it only gets difficult when the engine is running it's because the input shaft on the transmission is still spinning, even though you've tried to disengage the clutch.

You can try pumping the clutch pedal a few times, too. If that helps it's probably a failing master cylinder seal.

 

[schumicat]

when I changed trans fluid on mine last year I was going to try to bleed the hydraulic fluid (brake fluid, uses same reservoir as brakes) but there doesn't seem to be a bleeder nipple for the slave cylinder that I could find.

 

[300DFan]

I haven't needed to bleed my clutch hydraulics yet but there should indeed be a bleed nipple on the slave cylinder.

The w203 uses a combination release bearing/slave cylinder assembly that is entirely inside the bell housing. You need to pull the transmission to replace it, but I'm almost certain there's an access port to bleed it.

That would be worth trying as well. It really shouldn't have air in it but if it does that could these symptoms, too.

 

[schumicat]

I followed the fluid line into the bell housing but didn't see any place to bleed it. It would seem odd not to have one but I couldn't find it.

EDIT searching the intertubes it says the bleeder nipple is behind a square rubber plug on the bell housing.

I haven't needed to bleed my clutch hydraulics yet but there should indeed be a bleed nipple on the slave cylinder.

The w203 uses a combination release bearing/slave cylinder assembly that is entirely inside the bell housing. You need to pull the transmission to replace it, but I'm almost certain there's an access port to bleed it.

That would be worth trying as well. It really shouldn't have air in it but if it does that could these symptoms, too.

 

[Masec200]

I have the exact same problem on my 2011 w204. Did you find a fix in the end?