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Discussion Starter · #1 ·
Hi All,

I have always wanted a 3 pedal setup on this car as the 4 speed auto saps all the power from the amazing M104 and it is just waiting to be liberated with a proper tranny. I was lucky enough to be able to locate a 2.3-16v manual transmission with all parts late last year, I wasted no time and bought it immediately. The conversion took about 3 weeks working on the weekends. I ordered a custom flywheel for the setup, here are some pictures from the conversion:
The parts:
20201031_072417.jpg


20201031_072807.jpg
20201031_073248.jpg


The single-mass flywheel:
20201031_073258.jpg


New OEM Clutch:
20201031_073255.jpg


New Pressure plate:

20201031_073252.jpg


The Tranny:
20201031_073312.jpg


The Shifter:
20201031_073348.jpg


The Mileage:
20201031_073612.jpg
 

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Discussion Starter · #2 ·
The linkage setup:
20201030_120015.jpg


The flywheel setup:

20201030_122538.jpg


Good bye buddy!!
20201031_073615.jpg


First the exhaust, then the first transmission bolts:
20201031_080602.jpg


Tranny's off!!

20201031_143708.jpg


New Slave:

20201102_123133.jpg


New hydraulic line from the brake reservoir:

20201102_132734.jpg


New flywheel, clutch, flywheel all in:
20201031_132547.jpg


Old shifter out, new one in:
20201114_152937.jpg


The shiftrod linkage setup:
20201122_084132.jpg
 
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Discussion Starter · #4 ·
I needed to use the front half shaft from a W201 and relocate the centre support bearing back by a few inches.

The issues I am having new is that the clutch only engages when it is pressed completely into the carpet, if I even move it up by a few mm it will engage and start moving forward. I am not sure if the slave cylinder rod length is insufficient, or if the flywheel is thinner than it is supposed to be.

Any help would be appreciated. Other than that the M104 has really woken up and feels extremely lively this car is so much fun to drive now. This is the best thing you can do to any older Mercedes!
 

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W163 and General M Gremlin
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Nice posting.
Keep us updated on your progress and findings with the gearing setup with this on the 320e.
I've heard/read opposing comments with a swap like this, and not enough info to make a judgement on it.
 

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95,94,93 e320/300e
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Sweet deal. Been hoping someone will put together a t5 adapter kit someday.
 

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Discussion Starter · #7 ·


Two great resources that list out all the parts with numbers, these sites gave me the confidence to proceed with the swap.
 
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W201 Moderator
89 190E2.6- 5-speed Manual - 200K miles, 95 E320 Sportsline-sold, 2001 E320 4matic Wagon-sold
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Congratulation's on the swap. If the rest of the car holds up, you know have a transmission that will outlast the car. My original (with original friction plate and pressure plate) is at 200Kmiles now.
Though it is a W201. You may have similar clutch issues to another forum member on the W201 side. His was also a swap:

 

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Discussion Starter · #9 ·
Congratulation's on the swap. If the rest of the car holds up, you know have a transmission that will outlast the car. My original (with original friction plate and pressure plate) is at 200Kmiles now.
Though it is a W201. You may have similar clutch issues to another forum member on the W201 side. His was also a swap:

Thanks bud, I have been trying to find the longer rod for the slave cylinder. I am also trying to find the shifter bracket that holds the leather gator to the wood panel.
 

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Your mom
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I needed to use the front half shaft from a W201 and relocate the centre support bearing back by a few inches.

The issues I am having new is that the clutch only engages when it is pressed completely into the carpet, if I even move it up by a few mm it will engage and start moving forward. I am not sure if the slave cylinder rod length is insufficient, or if the flywheel is thinner than it is supposed to be.

Any help would be appreciated. Other than that the M104 has really woken up and feels extremely lively this car is so much fun to drive now. This is the best thing you can do to any older Mercedes!
Try rebleeding the clutch. I ran into a similar problem with my 300D 5 speed swap. Access to the bleed screw on the slave cyl was a royal PITA and it took me a few tries before I had it bled properly. You need a helper to press, release, press, release the clutch pedal over and over while you fiddle with the bleed screw from underneath.

Awesome project by the way. What RPM are you running at 60 or 70mph in 5th? If I remember correctly the dogleg box has 1:1 5th gear? The 320E-24 (not a typo) was available with this very dogleg box from the factory but even in europe it was an extremely rare option.
 

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Discussion Starter · #11 ·
Try rebleeding the clutch. I ran into a similar problem with my 300D 5 speed swap. Access to the bleed screw on the slave cyl was a royal PITA and it took me a few tries before I had it bled properly. You need a helper to press, release, press, release the clutch pedal over and over while you fiddle with the bleed screw from underneath.

Awesome project by the way. What RPM are you running at 60 or 70mph in 5th? If I remember correctly the dogleg box has 1:1 5th gear? The 320E-24 (not a typo) was available with this very dogleg box from the factory but even in europe it was an extremely rare option.

Thanks, I have bled the clutch, no difference, reverse bled, little difference. Finally I power bled the system and it made a whole lot of difference. The engagement pointe is still mashed into the carpet though, but much smoother and uniform.

RPM - It is much lower now on the highways, gets up to 100 very quick, it does have a 1:1 5th. Love the tranny, 99% there, just need to sort out the last 1%.
 

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W201 Moderator
89 190E2.6- 5-speed Manual - 200K miles, 95 E320 Sportsline-sold, 2001 E320 4matic Wagon-sold
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I'm guessing you have a similar issue with the W201 thread I posted. The Saab900 also tried bleeding, power flushing etc and even replaced master/slave cylinders to no success.
Until he fixed the mechanical mismatch with the clutch. That is my recollection.
 

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You could place a couple of washers between the slave cylinder and the bell housing to move the slave cylinder back and adjust the clutch pickup point. Not ideal but it might allow you to find exactly how much adjustment you need.
 

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94 E320 5 spd conversion
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Congrats! Pleased to see another USA 5 spd out there. When I did mine I used the overdrive 5 spd from an 88 300E. My commute at the time was almost all limited access freeway (well, not free but EZpass express lanes are a wonderful thing). 80MPH in 5th is around 2300 rpm. To help finish it up, the plastic piece that will hold the shift boot is 124 683 03 06.
 
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Discussion Starter · #15 ·
You could place a couple of washers between the slave cylinder and the bell housing to move the slave cylinder back and adjust the clutch pickup point. Not ideal but it might allow you to find exactly how much adjustment you need.
I think I need to find a slightly longer slave cylinder rod, I will try and locate one, my slave is from a 201 with a 202 updated part number.
 

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Discussion Starter · #16 ·
My dogleg shift knob was knackered and really let down the interior. After searching everywhere and refusing to pay upwards of $400 for a factory replica, I finally found a German website that custom builds new ones. They are a little modern for my tastes, but look a heck of a lot better than the worn out factory one. Here is the site:

shift gear knob E-Class W124 replacement gaiter

20210226_145854.jpg
20210226_150102.jpg
20210227_092629.jpg
20210227_133946.jpg


The great thing is that they are back lit and I can finally reuse the auto light wires to illuminate the knob!
 
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Damn, I need to clean my car.
 

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1977 W123.123 1995 W124.034
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Awesome project! I did a 5 speed conversion as well a number of years ago on my former 91 300TE and definitely miss that car. Only sold it so I could get a V8.
 

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I used this shift knob and gator on my124 300D 5spd swap. I know it says 6spd but you could use just the gator with the knob you already have. The gator is a perfect fit for your center console. It just clicks in.
 

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Discussion Starter · #20 ·
My tranny is a dogleg, so 1st is left and down and reverse top left. Options are very limited for these.
 
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