Are you experiencing issues with your Mercedes W201 5-speed manual shifter? Owners of the classic Mercedes-Benz W201, also known as the 190E, might encounter problems with gear shifting over time, especially with the 5th gear and reverse. If you find yourself struggling to engage these gears smoothly, often needing to double-clutch or feeling a notchy sensation, your shifter might be in need of refurbishment. While a gearbox synchromesh problem could be the culprit, often the issue lies within the shifter mechanism itself.
This guide provides a step-by-step process to refurbish your Mercedes W201 5-speed shifter, addressing common problems and restoring smooth, precise gear changes. This DIY refurbishment can save you money and enhance your driving experience in your beloved W201.
Before starting, ensure you have safely removed the shifter from your Mercedes W201. If you are unfamiliar with this initial step, the following image illustrates the shifter removal process.
Important Preliminary Step: Reverse Light Switch Removal
Before proceeding with the shifter disassembly, it’s highly recommended to remove the reverse light switch. This prevents accidental damage to the switch during the refurbishment process.
Disassembly Process
Now, let’s move on to the disassembly of the Mercedes W201 5-speed shifter. Follow these steps carefully:
- Initial Disassembly: Begin by observing the shifter assembly. You’ll notice the initial stages of deconstruction involve easily accessible components.
- Remove 10mm Bolts: Locate and remove the two 10mm bolts that secure part of the shifter mechanism.
- Spring Loaded Component: Be aware that the assembly is spring-loaded. However, the spring tension is minimal, so proceed without excessive force.
- Component Removal: The parts should come out relatively easily once the bolts are removed and spring tension is relieved.
- Shifter Rod Levers: The levers for the shifter rods will come out as a group. Pay close attention to the orientation of washers and spring washers during removal to ensure correct reassembly.
- Securing Washers (Optional): To keep the washers in order, you can use a glove or tie wraps if available to maintain their sequence and orientation.
- Remaining Washer: It’s common for one washer to remain after removing the main group.
- Plastic End Cap Removal: Remove the clear plastic end cap from the shifter assembly.
- C-Clips and Retaining Pin: Carefully remove the fiddly C-clips located on either end of a retaining pin. Two small electrical screwdrivers can be helpful for this task.
- Keep C-Clips: Retain the small C-clips, even though replacement clips are often included in repair kits. It’s always good to have spares.
- Torx Screws: The next step involves removing two Torx headed screws. Take care to maintain the position of components on the shaft during this step.
Shifter Shaft Measurement (Potentially Optional)
While initially thought necessary to measure the shifter shaft clamp position, it might not be crucial for all refurbishment processes. However, for peace of mind, measurements were taken. The shorter length was approximately 34mm, and the longer length around 69mm.
Choosing the Correct Repair Kit
When sourcing a repair kit for your Mercedes W201 5-speed shifter, ensure you select the correct one for your specific model and gearbox configuration. The part number 1242602539, as shown below, might not be universally compatible with all 5-speed shifters, particularly those with a standard gear layout. This kit is designed for a reverse gear located to the left and up, next to the 2nd gear position, which is less common.
Always verify that the repair kit is appropriate for your Mercedes W201 5-speed shifter type to avoid compatibility issues. Modifying an incorrect kit might be possible, but obtaining the correct kit from a Mercedes-Benz dealership or a reputable parts supplier is generally recommended for a straightforward refurbishment.
By following these steps, you can effectively disassemble your Mercedes W201 5-speed shifter as a crucial part of the refurbishment process. Further steps would involve cleaning, inspecting components, replacing worn bushings and parts from your repair kit, and reassembling the shifter, reversing the disassembly process. This refurbishment should significantly improve the feel and precision of your gear changes, bringing back the joy of driving your classic Mercedes W201.
