1982 Mercedes 240D Clutch replacement
need to replace the clutch in my 1982 Mercedes 240D, need to know if there are special tools and technique (s), want to know methodology.
The W123 chassis covers 240D's, 300D's, 300TD's, 280E's, and several other models of Mercedes coupes, sedans and wagons from model years 1977 to 1985.
Factory procedure assumes engine has been removed with transmission, but it is not required. Remove transmission after taking out necessary preliminaries (starter, driveshaft, exhaust, slave cylinder line, shift linkage, rear engine mounting bracket, etc.). To reach the top two bolts on clutch housing use a three foot (one meter) extension with a wobbly socket. Without this combination, reaching the bolts is very difficult. Transmission removal is straightforward, most common tools (ratchets, 3/8" and 1/2" sockets, metric hex wrenches, combination wrenches, etc.) will suffice. When replacing clutch, be sure to use new clutch release bearing (a k a throwout bearing) as well as new pilot bearing (that which is contained in end of crankshaft). Also inspect front and rear flex discs on driveshaft while you're under the car. For someone who has never changed a W123 clutch, expect process to take six to eight hours. I have seen the job completed in less than two hours by a factory trained Benz guru.
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