Mercedes W124 E300D estate - progress, or not...

Mercedes W124 E300D estate - progress, or not...

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Northbrook

Original Poster:

1,451 posts

66 months

Tuesday 8th December 2020
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Right then. Plans are afoot - car is booked for the gearbox swap next Wednesday (which will be the fourth car trip to the Man in less than three weeks - bargefleet mechanical planning at its best).

I have the replacement gearbox & torque converter.
The fluid should arrive in time.
I should be collecting the vacuum modulator, vacuum pipework (hard and rubber lines & junctions) from MB on Friday.
I've got the transmission mount and front flex disk.

I also have questions:

- Aside from giving the outside of the box a quick clean, it there anything else I should do to the box before install day?

- Is there anything I should check on the new box before we start? It's empty of fluid, so I don't know if it's feasible to check it rotates without graunching (?)

- Would it be worth replacing the front propshaft centering bush while the prop is disconnected?

Any & all tips are welcomed.

Thanks.

northwestrecovery

159 posts

187 months

Tuesday 8th December 2020
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Replace the input shaft / torque converter seal while its out .

Northbrook

Original Poster:

1,451 posts

66 months

Wednesday 9th December 2020
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I was having a chat with my Man on a similar topic yesterday. He was horrified when I mentioned that the torque converter is separate from the box on the one I've picked up, and he talked about the seal between the two.

As far as I understand it (but my knowledge is limited), the TC and box interface differently on these boxes to the norm. That's evidenced by the drain plug on the TC, which to me implies that it's not the same closed loop as the rest of the box. I could easily be wrong, though.

Here's the diagram of the central spinny bit of the box. I guess the seal (#20) would be the most likely seal if there is one...?

Northbrook

Original Poster:

1,451 posts

66 months

Wednesday 9th December 2020
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northwestrecovery

159 posts

187 months

Thursday 10th December 2020
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Yes that's the seal , pump input/ torque converter seal and usually gets damaged when converter is removed . The system is all one , the drain plug is just to empty the converter .

Northbrook

Original Poster:

1,451 posts

66 months

Friday 11th December 2020
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Thank you kindly - I've got this orange seal on order with MB for collection tomorrow, along with the dipstick O ring I forgot to order.



Shame I forgot the centering bush - still not sure if it's worth bothering to replace, the MB dealer will get it in time but it means another hour round trip, and I'm very time-poor at the moment. (Not the only kind of poor, to be honest!)

Here are some of the bits ready to go. This was before I went to get the first & second round of bits from the dealer.....




...and the old box is definitely on its last legs, as the MB gentlemen had to push me out of the parking space! It would appear that the box has gone far enough that reversing up hill with another gearbox in the back was too much for it. A little embarrassing....

Anyway: gearbox and TC are tucked up safely with The Man. Other bits will be in the boot when I drop it off on Tuesday (assuming the car will reverse out of its current space). Fingers crossed it won't be too hard a job to swap and, more importantly, to set up and get running smoothly.



Blackpuddin: your glow plug question. From memory, my Man did the disassembly to ease access, then got Thread Doctor (https://threaddoctorservicesltd.co.uk/) to come and remove the plugs themselves. It wasn't the cheapest thing I've had done but not the most expensive either - I think it was around £80 per plug plus the labour to expose them and build back up. The TD was quite experienced with this engine type, I believe, so told my Man what to remove so he could Milk Tray Man in to the rescue. Hope this helps - let me know if you're in the south east and would like my Man's details.

Northbrook

Original Poster:

1,451 posts

66 months

Friday 25th December 2020
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Some substantial changes, and a one-step-back situation.

Where to start?

So. Gearbox was done, and relatively painlessly from the sound of it. Some bolts were hard to get to, but otherwise the changing over of the boxes wasn't too bad. The Man didn't use all the parts I supplied - not sure why - so I have the vacuum lines, connectors & dashpot still to do at some point.

Is it better? Yes....and no.

When I arrived to collect the car, The Man had finished for the day but his son talked me through the job. He'd tried to adjust the gearbox so it was shifting at the right points, but had only got so far. I set off to head home, and the adjustment wasn't even close!

These boxes use vacuum - via the modulator on the side of the box - to control the shift harshness, and a bowden cable connected to the throttle linkage to determine the shift timing.

My wanderings to juggle cars meant that I had some time while walking to collect the car to determine that the cable was probably not right, which is why my brief drive was so odd. I got to the car and, sure enough, the cable adjuster was wound out a good inch. I wound it in half an inch, and the shift timing is now there or thereabouts. I'll have an incremental fiddle with it from there, but it's pretty good now.

What isn't so good is the harshness of the shifts. Unfortunately, they took the modulator housing off the old box, so I can't compare, but the adjustment on the new modulator on the new box isn't right. I've had the car in the air and wound the modulator back (turned the adjuster knob anti-clockwise to its stop), but I think I need to take the adjuster know off and wind the inner adjuster further back before refitting the knob. I'm just not sure if the knob is single-use and I should get another before making a start.

Annoying, but it'll get there.

But the car still has driveline noise!! Similar to before, not identical, but strongly there. There's also a noticeable roughness about 60-70mph. I mentioned the former to the Man, who commented that the diff has lots of play. Not sure why he hasn't mentioned it before, but that's the next place to look, I guess.

Frustrating.

I've managed to source a replacement secondhand diff for £100, but the current restrictions mean I'm not willing to get it until things settle down. Fingers crossed it's a decent one. I presume the alternatives are wheel bearings or propshaft...?

The old gearbox doesn't have any play in the output shaft, I'm told, but its problems with going into reverse means there's a problem somewhere in there. Interestingly, it's not the original box - not only had someone been in there before, the serial number is different to the one originally fitted. Who knows how many miles it has on it.

Moving on for now, I did a couple of jobs earlier in the week that I'll post when I have the photos, but I've changed the suspension fluid today. Nice easy job - as r129sl says, the hardest bit is putting the rocks in the boot. In my instance, the rocks were the old box and my ramps.













Nice straight-forward job (once one of the wise men of the E300D scene tells you what to do. Old fluid was a bit dark; new fluid is a nice pale straw colour. I believe heat will darken it down, but three litres of new fluid won't do any harm.

And then I'm amassing some bits for next year:





I'll need to get the looms and sundries for the cruise control retrofit, but a working brain and NOS lever is a good start, to go with the actuator I've got tucked away.

Outside temperature setup is, I'm told, complete aside from a couple of screws. I'll have to work out how to fit it, but it came with wiring instructions. A steal at £50 delivered.

Northbrook

Original Poster:

1,451 posts

66 months

Saturday 26th December 2020
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A couple of other little jobs done, and a quick win.

Job 1: throttle pedal clip. Old and new:



Job 2: EGR valve gasket. Likewise:



I am still noticing some wisps of smoke from the exhaust manifold area on startup. Don't think it's water evaporating off the exhaust. I wonder what it is.

One observation before today's quick win: the engine isn't entirely happy. Starts up fine, then the missing becomes noticeable around 30secs in, and the engine rocks until things settle down. I hope that it's an injector that isn't doing its thing properly until the engine is warm enough that it doesn't matter. I will be looking to get the injectors refurbed in the new year, and I'm planning to order replacement engine mounts once Autodoc has a good discount on.

And the quick win: I suspect the Man Jnr mucked about with the throttle adjuster when he was mucking about with the box adjuster. The box cable was too tight; the throttle has gone back to normal with an extra turn to tighten it up. Interesting how that turn of the adjuster - what's that, 1mm of travel? - resulted in the engine feeling lazier, reluctant to get going, and down on power. Normal service is resumed. Yay!

Just the bad noises to sort out. And clean the interior again. And the paintwork. And...

Northbrook

Original Poster:

1,451 posts

66 months

Sunday 7th March 2021
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Not much has been happening with the car itself recently - work has been hectic, plus lockdown, but I've been taking it for a little spin every now and again. I love driving this car, even with its faults. Even with the glaring faults. And I don't even mean the bad paintwork or the hole in the wing.

But anyway.

I've been steadily amassing bits and pieces, and am hoping to get it booked in fairly soon to get some stuff done. I'm considering enlisting the help of Wayne Gates this time, as I think the car would benefit from some specialist knowledge and I haven't been entirely enamoured of other specialists as of yet (just because I think they're too busy to do more than the obvious job).

So.



We have:

- A replacement secondhand, hopefully working better, centre vent. It'd be nice to be able to turn off the fresh air flow, albeit that's most important in the season that's just gone.

- Engine mounts.

- The rear wheel closing panels from a coupe. I'm hoping these can be persuaded to fit and cover the mud traps in front of the rear wheels, or used as inspiration for something home-brewed.

- More bits of below-windscreen trim. One is the cover for the fan, which I suspect isn't there; the other is the piece that directs the air flow from the grilles around the wiper arm down to the fan area. I suspect this isn't there either: when turning in the fan, I often get a gust of damp air onto the windscreen, so I think water is collecting in that area.

- A Hirschmann 6000KE aerial, which doesn't work. I nabbed it on eBay for twenty-something quid as not working, suspected dodgy control board (the black box on top). I then bought a tested & working control board from a seller in the States. Can anyone give me any tips as to how to test the aerial before bolting it in? The one in the car has stopped working and has a rat's nest of wires around it, so it'd be good to know that the new aerial operates before going any further. I'll need to dog out the MB rubber, but that'll seal up another possible water ingress point.

Still working on the diff...

anonymous-user

57 months

Sunday 7th March 2021
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What make of engine mounts have you gone for Northbrook? I'm intending to change the ones on my W220 sometime soon, and was thinking of Lemforder or Febi, but I've been reading that Lemforder quality might be heading downhill as people are saying they are sourcing parts from low quality manufacturers.

Blackpuddin

16,789 posts

208 months

Sunday 7th March 2021
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Northbrook said:
Blackpuddin: your glow plug question. From memory, my Man did the disassembly to ease access, then got Thread Doctor (https://threaddoctorservicesltd.co.uk/) to come and remove the plugs themselves. It wasn't the cheapest thing I've had done but not the most expensive either - I think it was around £80 per plug plus the labour to expose them and build back up. The TD was quite experienced with this engine type, I believe, so told my Man what to remove so he could Milk Tray Man in to the rescue. Hope this helps - let me know if you're in the south east and would like my Man's details.
Sorry, only just saw this! Thanks for the Thread Doctor lead, he sounds good. Unfortunately I live in south Wales so the search for a more local one will probably have to continue, but I will check TD out in case he can help with more leads. Hope your wagon is going well. I've just replaced the aerial on mine and eventually the bonnet star badge after wasting my time with two rubbish chrome-plastic ripoffs. The original part was harder to fit than I expected thanks to a piece of bonnet reinforcement metal that really got in the way of the pliers but seeing the star back in place makes it all strangely worth while.
ETA had the engine and gearbox mounts replaced last year, that made a big difference to the drive.

Edited by Blackpuddin on Sunday 7th March 13:34

Northbrook

Original Poster:

1,451 posts

66 months

Monday 26th April 2021
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SEGit: Lemforder. I don't have any experience of engine mounts in the wild, but these look pretty solid.

Just bought a diff. Not the one I was stalking, but that may still work out (in which case it'd be available to a fellow sufferer).

To celebrate Drive It Day yesterday, I had my own version: Sod It Day. While out for a local drive - to keep the car ticking over until getting some things sorted, and because I love driving this car - I set off from a standstill after the usual 'let one through, three more bully afterwards' my-right-of-way situation....with the wheels pointing toward the kerb. First time I've kerbed a wheel in several years.



On the positive side, they're kerbed anyway.


Northbrook

Original Poster:

1,451 posts

66 months

Sunday 2nd May 2021
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Some diff progress: now I have a tommy gun.

I mean: now I have two spare diffs!

And neither is the one I was stalking.

I bit the bullet and BINed what looks to be the right estate diff (3.07 ratio). While I was at it, I also BINed another diff, for a sixth of the price, from a guy in Addlestone who buys job lots of abandoned packages from the likes of the Royal Mail or Parcelforce.

So, the 3.07 (more expensive) diff - my scientific method of turning the input end resulted in smooth, albeit slow, rotation of the drive ends (sides), so it seems to be okay without any graunching....but what do I know? Seems a little greasy on the back cover, so I don't know whether it needs any attention before it can go on a car.



The cheaper diff is a 2.87, which means it's from a saloon. If anything, it's in marginally better condition. The guy seemed genuine - I collected from a Victorian terraced house in Addlestone, rather than some dodgy lockup - and again it seems to spin fine.


Northbrook

Original Poster:

1,451 posts

66 months

Sunday 23rd May 2021
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A very long day house hunting gave me a couple of great drives yesterday.

As recounted on the barge thread, I decided to take this car for my all-too-often circuit of house viewings this weekend. I've taken the Lexus for the first 6 trips, and both the cruise control and comfy seats are very welcome, but I was tired of throwing about £150 of petrol in for the 500-mile circuits. So I decided to take this car this time, as it was just me. Bold, considering this car's lack of cruise control and noisy diff, but I hadn't had a good drive in the car in a long time.

Come Friday night, en route to my overnight stay in Telford, I was very worried that this was the wrong move.

Once up to motorway speeds for the first time (and the first time in months, perhaps even 18 months) there was a worrying amount of noise and vibration. Is it the diff, I wondered, or something else going wrong? I pulled into the services, checked the tyre pressures (all a little low) and carried on in sublime ignorance. If I kept below 55ish, the more worrying noise wasn't as evident. So I did that. But, thanks to road closures, reduced speed, and bad weather....my 2.5hr trip became nearly four. But hey ho - only another 350 to do.

First of all, an early-ish morning flow from Telford to Lake Vyrnwy - A5, then mostly B4396 through Knockin, Llynclys, Llanyblodwel, into Wales at Pen-y-bont, Pen-y-bont Fawr, then drop down to the reservoir via Hirnant. Didn't quite make it to Penisarcwm. Truly lovely to have the start of the Welsh hills unroll in front of me. Not fast - mid 40s to mid 50s - but lovely and flowing, with little traffic on the road pre 8am. I kept a Discovery 4 honest, despite my NA diesel, four speed auto with optional jerky shift, and aging diff.



With some time to kill for the only time yesterday, I breakfasted on water & crisps while I had a walk around the lake.







It was then time to slip over Bwlch Y Groes (aka Hellfire Pass, the second highest public road mountain pass in Wales) to my first viewing.

[url]

|https://thumbsnap.com/j1UTGo2d[/url]



After that, it was the work of but a moment to rejoin the A roads, stopping in Dolgellau for a proper breakfast at TH Roberts before viewing 2 in Corris.

I would provide photos, but to be honest I can't really do the area justice while behind the wheel (perhaps never) and I was on a strict timeline at this point.

Corris viewing done, off back north to Trawsfynydd. Not a bad view from the back garden:



I then took a moment, rather than go back down the same road, to meander onto unclassified roads at Bronaber, wiggle around Abergeirw and behind the Coed y Brenin mountain bike centre, before heading back onto the A470 below Ganllywd heading to Dolgellau for a coffee.

Turns out I didn't really have time for any of this recreational nonsense.









From there, I had to make tracks to a village outside Machynlleth for my final viewing.



That done, at 7.30 it was lunch time.



After that, it was time to head home.

Perhaps just got in a couple of drive-by viewings, though, because there's always time for that. Right?

Mach to Commins Coch. Didn't even stop for that house. Along the A470 to Llanbrynmair, then right onto the B4518 and time for another joyful drive down past Llyn Clywedog to Llanidloes, flirt with the A470 for its width before plunging down through Pant-y-Dwr and the like, and into Rhyader. Back onto the A470, and down to Newbridge-on-Wye for my last drive past at about 10pm. Then just the 170 miles to get home.

Except it wasn't. Somewhere near Three Cocks, the road was closed, and I took a wrong turning during the diversion. By the time I could turn around on the A40 south of Brecon, my sat nav had given up on telling me to turn around, so we headed through the Brecon Beacons on the A470, heading for the M4 in Cardiff. A quick stop for a fill-up (36mpg very impressive given the nature of the terrain) in Wales, and a stop or two for me, and I got home at 2.30 this morning.

But, you ask, what about the car? Shut up about the scenery and your incompetence, and tell us about the car!!

Well. The car is okay. Given I was considering throwing in the towel at the 25 mile mark, we got around the 560 mile circuit pretty well.

I didn't have music for the last couple of hours - the CD player seems to have jammed, and it wouldn't even turn on - and I generally kept below 60mph to keep the noises and vibrations to a mentally-bearable level, but we got back in one piece.

It's a good car.

CharlesdeGaulle

26,665 posts

183 months

Sunday 23rd May 2021
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Nice update. Good luck with the car and the house search.

Blackpuddin

16,789 posts

208 months

Sunday 23rd May 2021
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Yes thanks for that interesting post. We live in Powys with our 300 estate and the topography round here is very similar. Our car is going in for its free year-one rustproofing check next week and that should be about the time that I buckle down with the sander, Kurust, filler and paint in an amateurish attempt to get the old girl looking as good as it drives. We're supposed to be selling it this year to make way for a pickup for Mrs B's horsey activities, but I'm finding the prospect painful.

Northbrook

Original Poster:

1,451 posts

66 months

Sunday 30th May 2021
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Maybe a trailer would cut the mustard instead? I'm considering a tow bar for this car, but (1) I'd want a removeable-head one, and (2) I have two cars with tow bars already. Plus (3) there don't seem to be any aftermarket bars of the type I want left any longer.

Anyway, I had time for a little bit of tinkering today. I would have done more, but I put my back out earlier in the week so light duties it is. Except the garage door is broken, so is heavy and won't stay up, so that's hardly a light duty!

Anyway anyway. I think I mentioned some stickiness of throttle during my trip last weekend, so I thought I'd have a go at improving that, although I suspect the problem may be linked (pun) to the new but cheap throttle pedal I put on last year.

This car has a fully mechanical linkage - one of the things I appreciate about it - so I did what any home spannerer would do.

I got my balls out


of the socket joints, cleaned them all up, and put them back together. After I'd lubed them up, of course.




And then, of course, I went for a drive.

And have I fixed it?

Northbrook

Original Poster:

1,451 posts

66 months

Monday 7th June 2021
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The previous owner at f this car rang me up last week, out of the blue. (Hello Baldev!) He had a bunch of spare parts he'd bought for this car during the ten years he had it, and had upgraded some things along the way. He'd also bought, and partially stripped, a similarly Azurite Blue S124, albeit an E280, and had a good amount of parts stashed away.

But now he doesn't.

And I do.

:-D



I haven't had a chance to fully work out what I've brought home, but the haul includes a Hirschmann antenna (needing replacement mast), set of ribbed mats plus front footwell carpets, set of Sacco boards, estate boot floor boards, and so on.











I didn't even take a pic of the dashboard or centre console.

Various bits I'll be wanting to keep/use (mats, probably aerial, headlights are going to r129sl) but other pieces would be available to 124 owners for a consideration to the car's bork fund.

After that, Baldev and I chatted about our experiences with the car - which he never planned to sell, but life happened - along with the work each of us has done. Turns out the E280 donated its bootlid as it was in better condition, along with its leather steering wheel (with the airbag from the original wheel, to keep the silver star from the last of the W124 build run). Bit of a shame he didn't keep more of the car as it was being stripped, but nobody has unlimited space.

It also turns out that he now drives buses, after redundancy from his electrical engineering job, and has seen me driving around over the last couple of years. Nice to be able to keep in touch - I hope I can take him for a drive once the diff is sorted and the world permits.

Northbrook

Original Poster:

1,451 posts

66 months

Monday 14th June 2021
quotequote all
Work continues apace.

If the pace is very, very slow.


I've booked in for a workout (the car, not me) in a couple of weeks at Wayne Gates. I'm hoping they can solve the whining (the car, not me), do some general fettling, and get some jobs ticked off. I'll need to spend a morning digging out and prepping all the parts I've got for the jobs between now and then.

I think I've not mentioned my searching for cruise control gubbins. Having been let down a couple of times by suppliers who didn't have the access to the parts once they asked their supplier (why not run an availability check now and again?), I have.....been let down again on some cruise control parts.

But I'm getting closer. I now have the actuator (used), stalk (NOS), ECU, and one of the two wiring harnesses. Admittedly the one I have is a single wire, but hey. But I DO have the other, bigger harness (supposedly) on its way along with some other bits.

What I'm now missing for the cruise setup is 0145458432 (coding plug for the ECU), 1245457540 and 1245452840 (mounting brackets). I suspect the coding plug is important; I'm hoping the other bits aren't.

Fingers crossed the ordered bits arrive before the car goes in in two weeks.

r129sl

9,518 posts

206 months

Tuesday 15th June 2021
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The mounting brackets on the dash side are universal and it will just be a matter of getting a breaker to remove them, assuming they are not available new. I suspect they may be one of those parts which the dealer still has 20 of at 50p each. I have three old cruise control ECUs, none of which I would guarantee to be working, some of which have coding plugs, any of which you can have. I'll check them out and if the part numbers are correct (I suspect unlikely), I'll get them to you. It also wouldn't surprise me if the dealer still has coding plugs, although if so, they will no doubt be £600 or something absurd.

Any more thoughts on the diff and other bits? Is your spare diff from an E300 diesel saloon? I am in Bristol next week, which means some sort of trade is not impossible.