Is your Mercedes W124’s 5-speed manual shifter feeling less precise than it used to? Owners of the classic W124 often experience issues with the shifter, particularly with engaging 5th gear and reverse. These symptoms can range from a notchy feel to difficulty selecting gears, detracting from the smooth driving experience Mercedes-Benz is known for. While problems could stem from the gearbox itself, often the culprit lies within the shifter mechanism.
This guide provides a step-by-step process for removing and disassembling your W124’s 5-speed shifter to allow for refurbishment. By addressing worn bushings and components within the shifter, you can often restore the crisp, precise shifts your W124 deserves.
Before diving in, it’s worth noting that this guide focuses on the shifter removal process. Refurbishment typically involves replacing worn bushings and potentially other parts within the shifter assembly. A repair kit is usually required for a complete refurbishment.
Removing the W124 Shifter: Getting Started
The initial removal of the shifter assembly from your Mercedes W124 is straightforward. If you’re comfortable with basic automotive DIY, this stage should present no difficulty.
Caption: The Mercedes W124 5-speed shifter unit after removal from the vehicle, ready for disassembly and refurbishment.
Important First Step: Disconnect the Reverse Light Switch
Before proceeding further with the shifter removal, it’s crucial to disconnect the reverse light switch. This small electrical component is attached to the shifter assembly and needs to be detached to prevent damage during removal.
Caption: Detail view highlighting the reverse light switch on the Mercedes W124 5-speed shifter assembly, emphasizing the importance of disconnecting it before further disassembly.
Disassembling the Mercedes W124 5-Speed Shifter: Step-by-Step
With the shifter removed and the reverse light switch disconnected, you can begin the disassembly process. This involves carefully taking apart the shifter mechanism to access the components that are likely causing the shifting issues in your W124.
Step 1: Initial Disassembly
Begin by removing the two visible 10mm bolts. These are the first fasteners you’ll encounter when disassembling the shifter.
Caption: The initial disassembly phase of the Mercedes W124 5-speed shifter, indicating the location of the first two 10mm bolts that need to be removed.
Caption: A closer perspective on the removal of the 10mm bolts from the W124 shifter, essential for progressing with the disassembly.
Step 2: Spring Loaded Components
Be aware that the shifter mechanism is spring-loaded. While not under significant pressure, it’s good practice to be mindful as you proceed.
Caption: Illustration of the spring-loaded nature of components within the Mercedes W124 shifter, advising caution during disassembly.
Caption: Continued disassembly of the W124 shifter mechanism, depicting the separation of interconnected parts.
Step 3: Levers and Washers
The levers for the shifter rods will come out as a group. Pay close attention to the arrangement of washers and spring washers. While parts diagrams are helpful, noting their positions during disassembly will aid in reassembly.
Caption: Detailed view of the levers, washers, and spring washers within the W124 shifter, emphasizing the importance of noting their order for correct reassembly.
Step 4: Securing Components
Using a glove or similar method can help keep components organized as you disassemble the shifter further.
Caption: Demonstration of using a glove to keep small components of the W124 shifter organized during the disassembly process.
Caption: The small parts of the Mercedes W124 shifter neatly organized after removal, highlighting the benefit of careful disassembly.
Step 5: Plastic End Cap Removal
A clear plastic end cap can be removed from the shifter assembly.
Caption: Step in removing the clear plastic end cap from the Mercedes W124 shifter mechanism, part of the disassembly sequence.
Caption: A close view of the clear plastic end cap after its removal from the W124 shifter, showing a component of the shifter mechanism.
Step 6: C-Clips and Retaining Pin
Fiddly C-clips are located on either end of a retaining pin. These can be carefully pushed off using small screwdrivers.
Caption: Procedure for removing the C-clips from the retaining pin on the W124 shifter, utilizing screwdrivers for careful manipulation.
Caption: A detailed shot of the C-clip removal process from the W124 shifter’s retaining pin, emphasizing the precision required.
Step 7: Retaining C-Clips
Keep the small C-clips safe, even though replacement clips are often included in repair kits.
Caption: The small C-clips after removal from the Mercedes W124 shifter, recommending to retain them as spare parts.
Caption: More components of the Mercedes W124 shifter disassembled, showing the progression of taking apart the mechanism.
Step 8: Torx Screws and Shaft
The next step involves removing two Torx-headed screws. In the original forum post, there was a concern about losing position on the shaft, however, it was later found to be unnecessary to measure the shaft position.
Caption: Location of the Torx screws on the Mercedes W124 shifter that are next to be removed for further disassembly.
Caption: Process of removing the Torx screws from the W124 shifter, enabling access to internal components.
Caption: The shaft component of the Mercedes W124 shifter, partially disassembled to show internal parts.
Mercedes W124 Shifter Repair Kit
A repair kit is essential for refurbishing your W124 shifter. It’s important to note that the part number 1242602539 shown in the original post may not be correct for all 5-speed shifters, particularly those with the more common gear layout. Double-check compatibility for your specific W124 model and shifter type.
Caption: A Mercedes W124 shifter repair kit, cautioning to verify part number 1242602539 for compatibility with different 5-speed shifter configurations.
This guide has taken you through the disassembly of your Mercedes W124 5-speed shifter. With the shifter disassembled, you can now proceed with cleaning, inspecting, and replacing worn components using a suitable repair kit to restore smooth and precise shifting to your classic Mercedes-Benz. Remember to always double-check part compatibility and consult repair manuals for detailed specifications and torque settings when reassembling.
