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87 190D Turbo / 91 M5
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Discussion Starter #1 (Edited)
Hi all,

New here, I usually spend a lot of time over at Bimmerforums.

I got myself a 1984 190D 2.2 5-speed a month back and she has been treating me well. However, I don't like doing 3500rpm to go 80mph. I wanted to swap the stock 3.42 for a 2.85 from a '93 190E 2.6 automatic.

My stupid self finds out the flanges for the axle shafts are different between the two diffs and the 2.6 diff appears to be slightly longer. They look like they will both mount to the subframe OK, but the flanges won't bolt and the driveshaft will be too long.

Anyone have experience swapping a later w201 diff into an early one? Is there any way possible I can make the 2.6 diff work? I seriously do not want to put the 3.42 back in after all this work...

 

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I tell ya the 2.2 Diesel doesn't have much HP. I am not sure you want to go with that drastic of a gear change on it.

Hi all,

New here, I usually spend a lot of time over at Bimmerforums.

I got myself a 1984 190D 2.2 5-speed a month back and she has been treating me well. However, I don't like doing 3500rpm to go 80mph. I wanted to swap the stock 3.42 for a 2.85 from a '93 190E 2.6 automatic.

My stupid self finds out the flanges for the axle shafts are different between the two diffs and the 2.6 diff appears to be slightly longer. They look like they will both mount to the subframe OK, but the flanges won't bolt and the driveshaft will be too long.

Anyone have experience swapping a later w201 diff into an early one? Is there any way possible I can make the 2.6 diff work? I seriously do not want to put the 3.42 back in after all this work...

 

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87 190D Turbo / 91 M5
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24 Posts
Discussion Starter #3
This car is from 1984 and the gearing is a dead giveaway. This thing was designed with 50-55mph in mind.

90% of my driving is 75+ MPH. I'm set on the 2.85.
 

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Outstanding Contributor
600 (3.200 mm)
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1,542 Posts
It need replacing the axle and drive shafts. Also don't forget about replacing the speedometer (for correct indications of speed and mileage) from 2.6.
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And I agree, that 2.85 is too long main gear for 2.2.
 

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'85 W201.601; '13 X204.651
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745 Posts
I don't know if there is a direct swap of axle shafts available, but a simple way is to take both shafts to an automotive machine shop and have them cut, weld and balance the old shaft with the new 2.6 flange. I know that's possible but there could be a simpler way.

You're going to be much slower pulling away from a stop light!
 

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87 190D Turbo / 91 M5
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24 Posts
Discussion Starter #6 (Edited)
Everyone, thanks for the input. I am putting the 3.42 back in for now until I have a good plan to make that rear end taller.

Right now, bone stock, with 175/70/14 (23.65in dia.), .84 5th gear ratio, and factory 3.42:

5000 RPM 122.46 MPH
4500 RPM 110.21 MPH
4000 RPM 97.97 MPH
3500 RPM 85.72 MPH
3000 RPM 73.47 MPH
2500 RPM 61.23 MPH
2000 RPM 48.98 MPH
1500 RPM 36.74 MPH
1000 RPM 24.49 MPH

Same as above, with a 2.85:

5000 RPM 146.95 MPH
4500 RPM 132.25 MPH
4000 RPM 117.56 MPH
3500 RPM 102.86 MPH
3000 RPM 88.17 MPH
2500 RPM 73.47 MPH
2000 RPM 58.78 MPH
1500 RPM 44.08 MPH
1000 RPM 29.39 MPH

Look at that, just over 2500RPM to do 75MPH. That's the part that is appealing to me. As far as I know 2500rpm is more than enough RPM to keep the engine bearings happy and it is above the peak torque rpm of 2200.

Stock tire diameter, 2.85 rear, using 4.23 tranny gear (1st gear on 2.2 manual transmission):

5000 RPM 29.18 MPH
4500 RPM 26.26 MPH
4000 RPM 23.34 MPH
3500 RPM 20.43 MPH
3000 RPM 17.51 MPH
2500 RPM 14.59 MPH
2000 RPM 11.67 MPH
1500 RPM 8.75 MPH
1000 RPM 5.84 MPH

You guys really think it will be a significant issue? I don't think it will be an issue at all...but I am known to be wrong. Also this is my first M-B AND diesel car :)
 

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From the numbers it looks like it would basically be the same as if you were running the car car 1 gear higher for the same speed with the stock gearing. An easy way to test it out would be to run the car with current gearing 1 gear higher than you normally would.

So if you are normally in 3rd to run 35mph put it in 4th and drive 35 and see if the engine is lugging or if it feels ok.

Would be a lot of work to swap the rear only to find out you don't like how it performs after the swap.

Everyone, thanks for the input. I am putting the 3.42 back in for now until I have a good plan to make that rear end taller.

Right now, bone stock, with 175/70/14 (23.65in dia.), .84 5th gear ratio, and factory 3.42:

5000 RPM 122.46 MPH
4500 RPM 110.21 MPH
4000 RPM 97.97 MPH
3500 RPM 85.72 MPH
3000 RPM 73.47 MPH
2500 RPM 61.23 MPH
2000 RPM 48.98 MPH
1500 RPM 36.74 MPH
1000 RPM 24.49 MPH

Same as above, with a 2.85:

5000 RPM 146.95 MPH
4500 RPM 132.25 MPH
4000 RPM 117.56 MPH
3500 RPM 102.86 MPH
3000 RPM 88.17 MPH
2500 RPM 73.47 MPH
2000 RPM 58.78 MPH
1500 RPM 44.08 MPH
1000 RPM 29.39 MPH

Look at that, just over 2500RPM to do 75MPH. That's the part that is appealing to me. As far as I know 2500rpm is more than enough RPM to keep the engine bearings happy and it is above the peak torque rpm of 2200.

Stock tire diameter, 2.85 rear, using 4.23 tranny gear (1st gear on 2.2 manual transmission):

5000 RPM 29.18 MPH
4500 RPM 26.26 MPH
4000 RPM 23.34 MPH
3500 RPM 20.43 MPH
3000 RPM 17.51 MPH
2500 RPM 14.59 MPH
2000 RPM 11.67 MPH
1500 RPM 8.75 MPH
1000 RPM 5.84 MPH

You guys really think it will be a significant issue? I don't think it will be an issue at all...but I am known to be wrong. Also this is my first M-B AND diesel car :)
 

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If you can grab the axle half shafts from the 1993 car they should bolt up to the rest fine. Try and find the rear section of the drive shaft from a manual 2.6 or 2.3-16 and it should work. It's 2am, I'm tired and I'm going off memory but I believe that will all bolt up. I'll try and look up the info on Tuesday when I get back to work. You're also dealing with an 84 which is kind of an odd ball. Lots of parts are 84 specific. After 85 stuff is pretty interchangeable between the rest of the model years.
 

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87 190D Turbo / 91 M5
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Discussion Starter #9
marrymercedes,

That is what I wanted to hear. Looks like the diff cases bolt in the same pattern, my main concern would be the 2.6 manual driveshaft's length bolting up perfectly to the 2.2 manual tranny.

If you have access to the dimensions that would be great.
 

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87 190D Turbo / 91 M5
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Discussion Starter #10
All,

I am scrapping the 2.85 idea. After a cruise into and around San Francisco yesterday, I have decided that a 2.85 would be a terrible idea. A good gear in theory for the freeway, but in reality, I think it will fall short.

I almost had trouble launching from a stop sign at a 45 degree angle. Almost stalled it/trying not to burn the clutch, it's a fine line with such little power. Without that 3.42 in the rear I surely would have not been able to climb the hill.

On a brighter note, I found a 190D 2.2 1985 in the yard today, I immediately stole the cruise control rod (my CC now works!) and Klima relay (for an automatic, anyone need?). Unfortunately the sound deadening panels were missing, probably ripped off during processing or someone beat me to it.
 

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2000 C230 Kompressor, 2005 Volvo S60 T5 AWD, 1992 190E 2.3 -Totaled
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I think you made the right decision. That would have been a pretty big change in gearing.

All,

I am scrapping the 2.85 idea. After a cruise into and around San Francisco yesterday, I have decided that a 2.85 would be a terrible idea. A good gear in theory for the freeway, but in reality, I think it will fall short.

I almost had trouble launching from a stop sign at a 45 degree angle. Almost stalled it/trying not to burn the clutch, it's a fine line with such little power. Without that 3.42 in the rear I surely would have not been able to climb the hill.

On a brighter note, I found a 190D 2.2 1985 in the yard today, I immediately stole the cruise control rod (my CC now works!) and Klima relay (for an automatic, anyone need?). Unfortunately the sound deadening panels were missing, probably ripped off during processing or someone beat me to it.
 

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1984 190D 2.2
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2,458 Posts
All,

On a brighter note, I found a 190D 2.2 1985 in the yard today, I immediately stole the cruise control rod (my CC now works!) and Klima relay (for an automatic, anyone need?). Unfortunately the sound deadening panels were missing, probably ripped off during processing or someone beat me to it.
PM Sent
 
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