Is your Mercedes-benz W124 5-speed manual transmission not feeling as smooth as it used to? Specifically, are you experiencing notchiness in 5th gear or difficulty engaging reverse? Many W124 owners encounter these issues, which can often be attributed to wear and tear within the shifter mechanism itself, rather than deeper gearbox problems. This guide will walk you through the initial stages of refurbishing your Mercedes-Benz W124 5-speed shifter, focusing on disassembly. By addressing the shifter, you might be able to resolve those frustrating shifting issues and bring back the satisfying feel of your classic Mercedes manual.
Removing the W124 Shifter Assembly
Before diving into the refurbishment, the first step is to remove the shifter assembly from your Mercedes-Benz W124. This process is straightforward and requires minimal tools. If you’ve managed basic car maintenance before, this stage should be well within your capabilities.
However, before you get too involved in removing the shifter, it’s advisable to disconnect the reverse light switch. This small component is usually attached to the shifter assembly and can be easily damaged if overlooked during removal.
With the shifter removed and the reverse light switch safely disconnected, you can now proceed to disassemble the unit on your workbench.
Disassembling the Mercedes-Benz W124 5-Speed Shifter
Now we move onto the disassembly of the Mercedes-Benz W124 5-speed shifter itself. This process involves carefully taking apart the shifter mechanism to access the components that are likely causing the shifting issues.
The first step in disassembly is to remove the two easily accessible 10mm bolts. These bolts secure part of the shifter housing and are a starting point for accessing the internal mechanisms.
Be aware that the shifter mechanism is spring-loaded. While it’s not under extreme pressure, it’s good practice to be mindful of this as you remove components to avoid any unexpected releases.
With the bolts removed, the shifter components will begin to separate. The mechanism should come apart relatively easily, allowing further access to the internal parts.
The levers that connect to the shifter rods will now be accessible. It’s important to pay attention to the order and orientation of washers and spring washers as you disassemble this part. While parts diagrams are helpful, noting the arrangement during disassembly will aid in correct reassembly.
To keep the washers and small parts organized during disassembly, a simple trick is to use a glove to contain them. This prevents them from getting lost or mixed up.
Ensure all the small components are safely stored as you proceed further with the disassembly process.
A clear plastic end cap is another component that can be removed at this stage. This cap is usually held in place by friction or small clips and can be gently pried off.
Next, you’ll encounter fiddly C-clips on either end of a retaining pin. These clips can be carefully pushed off using two small electrical screwdrivers. Patience is key here to avoid damaging the clips or yourself.
These small C-clips are important to keep safe, even though replacement clips are often included in repair kits. It’s always good practice to retain the original parts.
The next stage involves removing two Torx-headed screws. Before doing so, it’s wise to note the position of the components on the shaft to ensure correct reassembly.
While measuring the exact position of the clamp on the shifter bolt might seem helpful initially, it may not be strictly necessary later in the process. However, for those who prefer detailed records, it can provide extra reassurance during reassembly.
Finally, you’ll likely want to use a repair kit for your Mercedes-Benz W124 5-speed shifter. Be aware that not all repair kits are universally compatible. The kit shown below, part number 1242602539, may not be suitable for all W124 5-speed shifter configurations, particularly those with reverse positioned in the more common location alongside first gear.
Ensure you identify the correct repair kit for your specific Mercedes-Benz W124 5-speed shifter model to avoid compatibility issues and ensure a successful refurbishment. This guide has covered the initial disassembly of the shifter, and further steps will involve cleaning, replacing worn components from the correct repair kit, and careful reassembly to restore the smooth shifting experience of your W124.
