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722.6 Transmission Swap Mercedes 190 2.5D W201

My 2.5D had a bad transmission . This is  a 722.4  4 speed vacuum and cable controlled transmission.  I think i drove the the Car 10K km since i have it.  The guy where i bought it from mentioned that the transmission had a had a leaking gearbox cooler in the past.  This means it had cooling fluid in the gearbox.

So then the chance is very big the gearbox is toast.  Coolign fluid will get in the clutch plates. The thing that i noticed is that the gearbox is starting to slip when i have done long distance driving  highway speeds.  when i then come to a stop shifting is getting a problem and it will slip a lot.

Also kickdown was not working, it was not reacting to the throttle cable, so at 30kmh it was already in 4 gear what is way to early. So the gearbox needed to go.  About 2 months ago i started to get parts together. Get and ofgear controller, shifter from w202. I had a spare V12 box for my V8 turbo,  also had an old 4cyl box with a 6 cyl bellhouse. but this Transmission i bought as a broken box many years ago for parts and the bellhouse, but never opened it .

because i wanted a nag 580nm box i bought an extra 722.626 from a 320cdi.

i had prepped the car with the ofgear TCU and the wiring like speedsensor and TPS sensor also put basic settings in the ofgear already. also had driveshaft made with a bigger hardy disc connection that would fit the new gearbox.

So gearbox drained and removed, cooling lines removed, drive shaft out.  gearbox down.  pretty easy few hrs work.

now the fun starts the 320cdi converter is to big to fit the om602 flywheel. i had a small converter laying around from the spare box that would fit the om602 flywheel.  But the next surprise was already there. The bellhousing of the 320cdi is  not bolting on the om602 engine

It is not the same?  very weird i always thought these where all the same.  the box is is from a om613 or om648.  So next step is using the smalle bellhousing from the spare 4 cyl box.  very handy is that 722.6 bellhousing swap is pretty easy to do in about 45min.

So this time the box would fit .  320cdi 722.626 housing with bellhousing from 4 cyl and torque converter from 4 cyl.

So everything mounted with custom transmission mount.  modified axle in place. Oil lines needed to be modified.  the banjo connections where bigger now M14  also i use 25cm hydraulic pressed hoses 1 side banjo connections oder side 10L connection the will fit the 10mm tubing

Everything connected and filled up  with oil.  It is ready to start up.  I had straight on vibrations.  What i later on found to be the exhaust mount. that was hitting the chassis on 2 points.

needed to filled op oil to about 7-8 ltr in total.  got good level around 20c on the cold oil, so first testdrive. I had no leakages no weird noises it is going in every gears.  no issues.

The only thing what i need to tune where my inputs.

If there are any questions just ask

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