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Om617a into 240gd with om616

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NorwayW461 240gd
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Om617a into 240gd with om616

Post#1 » Thu Aug 09, 2018 7:14 pm

Hey y'all. Ive been scouring this forum for a couple weeks to figure out how to do this, im going to post a task list below of what i've found. If i'm missing anything would you please let me know? Have om616 and 4 speed manual that keep me in second on any steep hills, and thats most of idaho.

1. Move mounts forward to allow oil pan clearance and change to trapezoid
2. Oil cooler hookup, prolly aftermarket
3. New radiator
4. 3 in free flow exhaust
5. Match balance flywheel from 4 speed manual to new donor from 300d.
6. Cut to fit front drive shaft and balance? Will this keep drive angles symetrical?!
7. Shift linkage fab or adjust for forward movment.
8. Is it worth it? Anything else or tips on how to actually do this stuff are welcome im not much of a wrench, but love tinkering on these mechanical beasts of burden

Thank you!
Idaho Thad
thumpersold@gmail.com

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G Nome
Posts: 3246

Re: Om617a into 240gd with om616

Post#2 » Thu Aug 09, 2018 7:28 pm

If you are saying is the engine upgrade worth it? I say hell yes. Will be super fun.

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kafkaonwheels
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Re: Om617a into 240gd with om616

Post#3 » Fri Aug 10, 2018 2:07 am

I would suggest keep the frame mounts on original location. Pieces to convert from donut to trapezoid are available from MB. One thread here: viewtopic.php?f=18&t=6458 If you really think you need to change engine location, do it with brackets between engine and rubber mount. I have OM617A on original 300GD location and with 2” inch lift springs have had no issues over 10 years.

Stock exhaust for OM617A is 2.5”, 3”pipe area is 40% larger, if you are not going for larger turbo and IP in future, might bit too much.

Why you need to cut front drive shaft? Transfer case is separate unit on G. You need new middle shaft if changing engine location. When modifying G original shaft you have to look out for splines what are covered with some sort of plastic, if melted the shaft is ruined.
1985 300 GD Turbo (Project)

blueg
Posts: 1006

Re: Om617a into 240gd with om616

Post#4 » Fri Aug 10, 2018 2:40 am

oil cooler hoses. 1 from GD 1 from sedan donor.

NorwayW461 240gd
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Re: Om617a into 240gd with om616

Post#5 » Fri Aug 10, 2018 7:01 am

Kafka, i thought i need to change mount location since 5cyl om617 is longer than om616 and also because of oil pan issue? So youre saying keep in same spot and just modify middle shaft (thats what i was thinking wrong words)
Thanks
Idaho Thad
thumpersold@gmail.com

blueg
Posts: 1006

Re: Om617a into 240gd with om616

Post#6 » Fri Aug 10, 2018 8:38 am

I bought a 280GE that had 617A conversion.
PO used 300GD motor mounts at the engine with no suspension modification.
My sump was disfigured and upper pan was cracked in several directions, welded and weeping badly.
I got new upper oil pan and sump then realized it would happen again if suspension were fully compressed.
Engine needs to move ahead about 3/4" or 1/2" if front diff cover is replaced with heavier cover that has no lip.
The diff cover can save alteration of accelerator linkage if your existing linkage has 1/2" adjustment to lengthen.
I purchased engineered motor mounts made for this installation but have since learned that 300GD motor mounts can have mounting holes to trapezoid rubber mounts elongated enough to slide the engine forward the 1/2".
What you can do and what you may need will depend on what was used to make the installation work this far.
Lifting the body/engine does move things farther apart but also alters some geometry in steering and driveline.
Larger bump stops on front axle will protect also but limit range of front axle articulation and range of compression.

NorwayW461 240gd
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Re: Om617a into 240gd with om616

Post#7 » Sat Aug 11, 2018 2:31 pm

Blueg very detailed and helpful. I will need to figure out if mounting location is same fo current om616 as it is for the 617 on the 300gd
Idaho Thad
thumpersold@gmail.com

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kafkaonwheels
Posts: 144
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Re: Om617a into 240gd with om616

Post#8 » Sun Aug 12, 2018 2:57 am

If I get my engine to frame, I will remove springs and see with my own eyes how much interference there will be between oil sump and differential housing. When I bought the vehicle it had pretty old and soft original springs but previous owner used the vehicle on off-road competitions and still there are no such marks on sump. Maybe been just lucky this far.

Another solutions would be to modify oil pan. Not sure where the picture came from but here is an example.
oil pan mod2.jpg
oil pan mod2.jpg (38.03 KiB) Viewed 40 times
1985 300 GD Turbo (Project)

blueg
Posts: 1006

Re: Om617a into 240gd with om616

Post#9 » Sun Aug 12, 2018 3:32 am

kafkaonwheels. I am not critical of or denying that what you advised is correct.
There are many solutions to this problem and all have their pros and cons.
Mercedes solution was 617 NA with shallow 1 piece oil pan. Turbo needs more oil.
Every transplant has it's own flavour depending who performed it and what material. equipment and budget was available to them. I offer my situation and best (to me) remedy I could source out in the time I spent researching a subject that is only really discussed on the G forums. If road driven and carefully off roaded I doubt this ever becomes an issue. But if front compression of suspension is maxed then it can be disasterous.

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