Experiencing issues with your Mercedes-Benz W201’s 5-speed manual shifter? Common symptoms like difficulty engaging 5th gear or reverse can detract from the driving experience of this classic vehicle. Before assuming a major gearbox overhaul, consider that the problem might stem from the shifter itself. This guide walks you through a DIY refurbishment of your W201 5-speed shifter, a process that can often resolve these issues and restore smooth, precise gear changes.
Removing the W201 Shifter Assembly
The first step is to safely remove the shifter assembly from your W201. This process is relatively straightforward and requires minimal tools. Ensure your vehicle is safely parked and the engine is off before proceeding.
Pro-Tip: Before fully removing the shifter, it’s advisable to disconnect the reverse light switch. This prevents accidental damage to the switch and simplifies the removal process.
With the reverse light switch disconnected, you can now fully remove the shifter assembly from your Mercedes W201.
Disassembling the 5-Speed Shifter
Once removed, place the shifter assembly on a clean workspace. Disassembly is the next phase, allowing for inspection and replacement of worn components.
Begin by removing the two 10mm bolts that secure the upper portion of the shifter.
Note that the assembly is spring-loaded, so carefully control the release as you remove the second bolt.
With the bolts removed, the components will separate, revealing the levers for the shifter rods.
Pay close attention to the arrangement of washers and spring washers as you disassemble. While Mercedes-Benz EPC diagrams are helpful, documenting the order will aid in reassembly.
To keep parts organized, especially small components, use a glove or parts tray to prevent loss.
Continue disassembly, noting the clear plastic end cap which can be carefully removed.
Further disassembly reveals more intricate components.
Small C-clips retain a pin within the shifter assembly. Use two small screwdrivers carefully to remove these clips.
Retain these C-clips, even though replacement clips are typically included in a shifter repair kit.
Next, you’ll encounter two Torx screws. It’s often unnecessary to mark the shaft’s position before removal, as precise measurements aren’t critical for reassembly in this particular model.
Refurbishing and Reassembling the Shifter
Inspect all components for wear, particularly plastic bushings and contact points. A shifter refurbishment kit, like the one shown, is highly recommended.
Note: Ensure the repair kit is compatible with your specific W201 5-speed shifter model. Kits can vary depending on the gear configuration (e.g., reverse next to 1st gear vs. standard layout). While some kits might require minor modifications for perfect fitment, they provide essential replacement parts to revitalize your shifter.
Reassemble the shifter in reverse order, using the new components from the kit. Lubricate moving parts with grease suitable for plastic and metal contact to ensure smooth operation. Once reassembled, reinstall the shifter in your Benz W201 and test the gear changes. A properly refurbished shifter should significantly improve the feel and precision of your 5-speed manual transmission, making driving your W201 more enjoyable.
This DIY guide provides a practical approach to addressing common shifter issues in your Benz W201. By following these steps, you can potentially avoid costly professional repairs and restore the satisfying mechanical feel of your classic Mercedes-Benz.
