Mercedes Benz Diesel engine and T5 in my SX4 (frame)- Future Project

[rollguy]

I will be putting an MB Diesel in my SX4 frame one day (Lord willing), and will be looking for a T5.  I am pretty sure I will not find a 3550 (or be able to afford one if I did).   I found an aluminum bell housing from an early 240 4 speed that will bolt up to my 4 or 5 cyl MB Diesel engine.  The bell is fairly short, so there is plenty of length on the T5 input shaft to fit a nice thick aluminum adapter plate.
Actually, I am thinking of just using the whole body (1980 MB 240D) and putting it on my existing SX4 frame.  It will not be an Eagle anymore, but a 4X4 Mercedes Benz 240D (that started life as a custom built full framed SX4).  I am just looking for ideas as to making the engine work with available transmissions (T5 & NV3550 seem like the only available choice right now).  
The other reason for this thread is to make the research available to others that may want to re-power their Eagle with an MB Diesel engine.  As far as I can tell, only a manual trans will work with this combo.  The MB automatics would necessitate the use of a "divorced" transfer case, as there are no MB trans tail shafts/housings that bolt up to any available transfer case.   As far as I know, all MB TC's are divorced (G wagon and Unimog).   The only available bell housing that I know of that will work comes from an early (up to 1978?) 240 4 speed with an iron case.  The later transmissions are all aluminum (bell and case in one piece). Photos:

[eaglefreek]

These guys have an adapter to use an AX15. http://mercedesdiesel4x4.com/OM617AdapterKits.aspx I considered it in the past, but after driving some of the company's diesel trucks cross country, I decided gas was for me. Too noisy and sometimes hard to find diesel. I'd like to see a 240d 4x4.   

[BenM]

There's a guy over at the TDI message boards who made adapters from the VW 1.9 turbo diesel to an AMC bell pattern, I believe he had an AW4 in a Cherokee.

I don't know much about the Mercedes engines. Are they all naturally aspirated?

[rollguy]

There's a guy over at the TDI message boards who made adapters from the VW 1.9 turbo diesel to an AMC bell pattern, I believe he had an AW4 in a Cherokee.

I don't know much about the Mercedes engines. Are they all naturally aspirated?

The 4 cyl (240D) are all N/A, and some 5 cyl (pre-'82 300D & TD).  The best one is the OM 617 TURBODIESEL found in 1978-1985 300SD, and 1982-1985 300D & TD.

[rollguy]

These guys have an adapter to use an AX15. http://mercedesdiesel4x4.com/OM617AdapterKits.aspx I considered it in the past, but after driving some of the company's diesel trucks cross country, I decided gas was for me. Too noisy and sometimes hard to find diesel. I'd like to see a 240d 4x4.   

Thanks for the link!  I am glad someone else has done the R&D.   However, I am a cheapskate, and may just try my idea out first. It may end up costing more in the long run, but I am willing to try first, and maybe learn something.  There are T5's out there that are cheaper than AX15's, so I may be able to do it cheaper.  It is nice to have another option though, and I may end up ordering the kit anyway!   The question is, does the T5 and AX15 share the same output shaft size and spline count?   I know a Dana 300 TC will bolt directly to a 998 with no mods, so I assume the Dana 300 will bolt to an AX15 with no mods as well.

[rollguy]

With more research and measuring done, the adapter from Koch Enterprises seems the best way to go, and one will be ordered soon.  I already have the AX15, and most everything else I need.  Stay tuned!

[vangremlin]

Good luck with this Rollguy! I'm looking forward to following your progress!

[Baskinator]

I got to see an '82 5 cylinder turbodiesel wagon up close for the first time the other day. Looks like a viable engine swap, at least in terms of size. Sure won't see any power increase, maybe a little better on gas mileage though. Good luck, it will be interesting to see this complete!

[carnuck]

No maybe about it. Should get close to 30 mpg

[mach1mustang351]

I've always wanted a diesel Eagle.  Very interested in your progress.  MAKE IT HAPPEN!!!

[rollguy]

I've always wanted a diesel Eagle.  Very interested in your progress.  MAKE IT HAPPEN!!!

Actually, it will not be a Diesel Eagle.  I will be using the frame and suspension from my old SX4 (avatar photo), and making a M B Diesel sedan 4X4.  The only real Diesel Eagles were very rare (I had one, Rambler Ranch has it now).  If I were to make one, it would have an M B 5 cyl engine.  I don't know if anyone else has done a Diesel Eagle conversion yet (other than the 5 or so done in 1980), but I would like to see one done and documented here.

[mach1mustang351]

I've always wanted a diesel Eagle.  Very interested in your progress.  MAKE IT HAPPEN!!!

Actually, it will not be a Diesel Eagle.  I will be using the frame and suspension from my old SX4 (avatar photo), and making a M B Diesel sedan 4X4.  The only real Diesel Eagles were very rare (I had one, Rambler Ranch has it now).  If I were to make one, it would have an M B 5 cyl engine.  I don't know if anyone else has done a Diesel Eagle conversion yet (other than the 5 or so done in 1980), but I would like to see one done and documented here.

It will end up having a diesel in it... close enough for me.   

[carnuck]

I was looking at an '80 Gwagen yesterday for $6,000 but it had rust issues (less than an eastern car, but still not impressing me) It was non-turbo 4 speed so 20 MPG is what it would get average. A 300TD motor and 5 speed would be nice, but I have a house to pay for. (to build that is)

[Baskinator]

Captspillane is also working on his SD33T Turbodiesel Eagle, along with a 401 V8 SX/4, Spirit-to-Eagle conversion, and MANY other projects. He will definitely have it documented here when it's finished, though I'm not sure how much free time he will have to do it along the way. I'd say it's probably going to be a year or two until that's complete, but it should be awfully cool when it is. I'm personally awaiting the 401 conversion, I can't wait to see an SX/4 with almost 400hp. I forget which one he's using for the Eagle, but he has a stock 401 to rebuild and a nearly perfect hi-po 401 to assemble.

I love these build threads, so neat to see how creative people can be!

[rollguy]

Captspillane is also working on his SD33T Turbodiesel Eagle, along with a 401 V8 SX/4, Spirit-to-Eagle conversion, and MANY other projects. He will definitely have it documented here when it's finished, though I'm not sure how much free time he will have to do it along the way. I'd say it's probably going to be a year or two until that's complete, but it should be awfully cool when it is. I'm personally awaiting the 401 conversion, I can't wait to see an SX/4 with almost 400hp. I forget which one he's using for the Eagle, but he has a stock 401 to rebuild and a nearly perfect hi-po 401 to assemble.

I love these build threads, so neat to see how creative people can be!

I have been following his threads.