Sunday, November 29, 2009

Mer-Chevy engine and tranny take-apart

I got some more work done on the Mer-Chevy Project this weekend.

Last weekend, we ran out of daylight before we could get the transmission off the S10 gasoline engine.

So, yesterday, I did the work of removing the tranny from the engine.


The transmission had some long bars that bolt the transmission to the engine.
After getting the two apart, I also removed the pressure plate, clutch plate, and flywheel from the gas engine.

The Mercedes diesel engine has lots of things still connected to it.
This image has been resized. Click this bar to view the full image. The original image is sized 1024x680.


The goofy round thing on the left/upper left is the air conditioning compressor. It also has a big metal bracket that wraps around the engine to hold it. I removed both the compressor and that bracket. The bracket bolts also held the water pump in. That started dripping coolant out on me when it loosened. I will have to get some shorter bolts to re-install the water pump.

The pulley in the lower right is the power steering pump. I removed that as well and both the belts still on the engine.

On the other side, I started working to remove the flywheel.

The flywheel is held on by a dozen 8mm hex socket bolts. I had to go out to the parts store to buy a male hex socket to fit those bolts.
I slid a long bolt through a whole in the flywheel, and through the starter motor hole to hold the flywheel in place while I turned out the bolts.

9 of the bolts came out fine (but boy were they torqued!) while three of them just stripped out. No way were those coming out now. I called Rich and asked for any advice on getting the bolts out. He suggested using a chisel and hammer to bite into the bolt heads and whack them counterclockwise.

I dug around and found a pointy chisel. I was amazed that the chisel really would bite into the metal of the bolt head. After some careful whacks, I actually was able to unscrew them!

With all the bolts out, I pulled the flywheel off.

Behind the flywheel, I was able to take out 4 bolts holding on the "transmission adapter ring" and smack it off with a rubber mallet.

Here's the drive end of the engine with the flywheel and tranny ring removed.
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Here is the ring that was removed.

It's all cast aluminum and fits directly to the engine block. I should be able to use this as a template to create a custom adapter plate between the Mercedes diesel and the Chevy manual transmission.

Here's a photo of the Chevy Tranny with the Mercedes adapter ring in front of it and the 2.2L gas engine in the background.
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I should be able to start work soon on designing the custom adapter plate between the diesel and the manual transmission.

Also, I need to figure out if I can find a flywheel off a Mercedes with a manual transmission, or if it is possible to modify the flywheel from the S10 to fit the diesel. I think that might be the tough part.

Does anyone know of a good forum for Mercedes diesels to ask questions and buy/sell/trade parts?

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