Is your Mercedes W124 5-speed manual shifter feeling less precise than it used to? Do you find yourself struggling to engage 5th gear or reverse smoothly? Many Mercedes W124 owners with manual transmissions experience these issues over time. The good news is that often, these problems aren’t due to major gearbox failures but rather wear and tear in the shifter mechanism itself. Refurbishing your W124’s 5-speed shifter can significantly improve shift feel and restore the enjoyable driving experience you expect from your classic Mercedes. This guide will walk you through the process of disassembling and refurbishing your Mercedes W124 5-speed shifter, addressing common issues and helping you bring back that crisp, direct gear selection.
Before diving in, it’s important to understand the symptoms of a worn shifter. Common signs include:
- Difficulty engaging 5th gear or reverse.
- Notchy or vague gear selection.
- Excessive play or looseness in the shifter.
- The need to double-clutch or hunt for gears.
If you’re experiencing these symptoms in your Mercedes W124, a shifter refurbishment might be the perfect DIY project to restore driving pleasure. Let’s get started.
The first step is removing the shifter assembly from your Mercedes W124. This is a straightforward process and requires minimal tools.
Ensure your Mercedes W124 is safely parked and the ignition is off before beginning any work.
Pre-Disassembly Preparation
Before you get too involved in removing the shifter, it’s advisable to disconnect the reverse light switch. This small electrical component is usually attached to the shifter assembly and can be easily damaged if forgotten during removal.
With the shifter removed and the reverse light switch disconnected, we can begin the disassembly process. This allows for a thorough cleaning, inspection, and replacement of worn components.
Disassembling the Mercedes W124 Shifter
Now, let’s move on to taking the shifter apart. This process involves several steps, and it’s helpful to take photos as you go to remember the order of parts for reassembly.
First, locate and remove the two 10mm bolts that secure part of the shifter mechanism.
Be aware that the mechanism is spring-loaded. However, the spring pressure is not excessive, so disassembly is safe and manageable.
With the bolts removed, the components will come apart relatively easily.
The levers for the shifter rods will then come out as a group. Pay close attention to the arrangement of washers and spring washers. While Mercedes-Benz EPC diagrams are helpful, noting the original configuration is invaluable for correct reassembly.
Using a glove can be helpful to keep components organized during disassembly.
Often, small parts like washers can stick to components. Be mindful not to lose any pieces.
A clear plastic end cap can also be removed for further access.
Next, you’ll encounter fiddly C-clips on a retaining pin. These can be carefully pushed off using two small electrical screwdrivers.
Keep these small C-clips safe, even though replacement clips are often included in repair kits. It’s always good to have spares.
The next stage involves removing two Torx-headed screws. It’s wise to note the position of components on the shaft before removal, although precise measurements may not be critical as the mechanism is somewhat self-aligning.
While measuring component positions might seem helpful, it’s often unnecessary for this particular shifter refurbishment (as learned later in the original forum thread). However, if it provides peace of mind, taking measurements is a harmless step.
Shifter Repair Kits and Component Replacement
A Mercedes W124 shifter repair kit is essential for this refurbishment. These kits typically include replacement bushings, plastic components, and sometimes clips and springs that are prone to wear or breakage.
Note: It’s crucial to verify that the repair kit you purchase is compatible with your specific Mercedes W124 5-speed shifter. There are variations, and the kit shown in the image (part number 1242602539) may not be suitable for all 5-speed shifter configurations, particularly those with reverse gear positioned to the left and up from 1st gear. Double-check compatibility to avoid ordering incorrect parts. Even if a kit isn’t 100% correct, modifications can sometimes be made to use the majority of the components, saving time and effort compared to sourcing individual parts or going back to the dealership.
By following these steps, you can effectively disassemble and refurbish your Mercedes W124 5-speed shifter. Replacing worn bushings and components with a repair kit will significantly improve shift feel and restore the precise, enjoyable gear changes that are characteristic of the Mercedes W124 driving experience. Remember to reassemble in reverse order, using your photos and notes as a guide, and enjoy the renewed precision of your classic Mercedes manual transmission.
