The next step is to improve launch and reduce slipping at gearchange by
changing the auto transmission to a 5-speed manual transmission. With a
little luck I might improve the top speed and fuel comsumption, too. I
have bought a transmission from the model 190E 2.6 (type 717.435) which
should endure a reasonable amount of torque. The clutch kit will be the
240 mm Sacsh 3000 824 202 or a copy which can take at least 232 lbft (315
Nm) of torque (Merc E220 CDI 1999-2002). The pedal assembly and the gear
change mechanism also need to be changed.
The manual transmission went in two times because there was problems wuth
the clutch slipping. The weight of the auto trans 722.4 with torque
converter, oil and flex plate was about 137 lb (62 kg). The weight of the
manual transmission is 66 lb (30 kg), the flywheel after machining
15 lb (originally 24 lb) and the clutch kit 13 lb (6kg). The total weight
changed from 137 lb to 94 lb which is a weight saving of 43 lb (19 kg).
Here is a picture of the lifting of the
engibe and the automatic transmission together.
Here are components of the pedal
assembly and gearchange mechanism I interchanged.
The clutch was slipping so I had to change it. The pressure plate is now Sachs Race Engineering model 88 3082 999
781 (Volvo T5). The clutch disk is a custom made for Mercedes 88 1864 999
998 (disk 88 1864 999 504/101 with hub 1848 999 092-931). The releaser
bearing is Sachs 151 248 031. After this mod the clutch is not slipping
I added a Davies Craig electrical water
pump EWP80 (in series with the original pump) with electronic controller.
The controller controls the electric water pump and the electric radiator
fan. The thermostat is removed and the bypass is blocked. I can now adjust
the engine temperature and the pump runs after the engine is stopped and
cools the system. This is a great system!
The car also has an OMEX Clubman Rev
Limiter with Launch Control which allows WOT launch and gear changes. It
cuts the ignition but does not retard the ignition timing.
The turbo is upgraded from TD04HL-13G
to TD04HL-19T by changing the compressor. There is still some work with
the boost control though.
I had only a few test runs this summer
2011 with the manual box and new turbo etc. The times were modest compared
to summer 2010. After the clutch slipping problems there was problems with
tyre grip. For the next summer I will install the LSD diff (Mercedes ASD)
and better rear tyres.