Pagoda Parts

The Mercedes 280 SL, produced between 1968 and 1971, is an iconic roadster, part of the W113 series, also known as the “Pagoda.” With its stylish design and engineering finesse, it’s no wonder that enthusiasts and collectors still hold the 280 SL in high regard. If you’re a hands-on owner or a professional mechanic working on this classic, installing Pagoda parts, like a new Clutch Disk for a 4 Speed Manual Transmission (0042501703), is an essential part of maintaining the car’s smooth operation. This article provides a detailed, step-by-step guide on how to replace the clutch disk on a four-speed manual transmission Mercedes 280 SL. Performing this task requires mechanical skill and the proper tools, but by following the instructions carefully, you’ll get the job done effectively and safely. 

Tools and Materials Needed

• Floor jack 
• Jack stands
• Basic hand tools (socket set, wrenches, screwdrivers) 
• Transmission jack (or another jack capable of supporting the transmission) 
• Clutch alignment tool 
• New Clutch Disk for a 4 Speed Manual Transmission (0042501703)
• New pressure plate (optional but recommended) 
• New release bearing 
• Torque wrench 
• Gasket sealer 
• Gloves and safety glasses – needed for all Pagoda parts installation

Step 1: Preparation 

Before you begin the installation, it’s crucial to have everything prepared. This means gathering the required parts and tools and ensuring the car is safely secured. Disconnect the negative battery terminal to avoid any electrical mishaps during the process. Any Pagoda parts that are not structural but rather mechanical, you need to do this prior to taking parts out or putting new ones in. You will also need to raise the car using a floor jack and place it on jack stands for proper access to the underside. Make sure you are working on a level surface to avoid the vehicle from shifting while elevated. Always use quality jack stands for safety. 

Step 2: Removing the Driveshaft 

With the car securely lifted, locate the driveshaft connecting the transmission to the rear differential. Before you can remove the transmission, you’ll need to detach the driveshaft. 

1. Unbolt the center support bearing: The Mercedes 280 SL has a two-piece driveshaft. Start by removing the center support bearing bolts. 
2. Disconnect the rear flex disc: Next, unbolt the flex disc at the rear, which connects the driveshaft to the rear differential. 
3. Separate the driveshaft from the transmission: At the front, unbolt the flex disc connecting the driveshaft to the transmission. Carefully lower and remove the driveshaft and set it aside. 

Step 3: Remove the Transmission 

Now that the driveshaft is out of the way, it’s time to remove the transmission. This part requires caution, as the transmission is heavy, so use a transmission jack to support it. Any heavy Pagoda parts that are being replaced should be supported by a jack or something to lower it or hold it in place depending on what is needed.

1. Disconnect transmission linkages: Begin by disconnecting the shifter linkage and any electrical connections to the transmission, such as reverse light wiring. 
2. Remove transmission mounting bolts: With the transmission supported by the transmission jack, unbolt the transmission cross-member and the bolts securing the transmission to the engine. 
3. Lower the transmission: Slowly and carefully lower the transmission from the car. Take care not to damage the input shaft or other components as you remove it. 

Step 4: Inspect and Remove the Old Clutch 

With the transmission removed, you now have access to the clutch assembly. This is the part that includes the clutch disk, pressure plate, and release bearing. 

1. Remove the pressure plate: The Clutch Disk for a 4 Speed Manual Transmission (0042501703) is sandwiched between the pressure plate and the flywheel. Unbolt the pressure plate from the flywheel, but make sure to loosen the bolts evenly in a star pattern to avoid warping the pressure plate. 
2. Remove the clutch disk: After the pressure plate is removed, you can take out the clutch disk. Inspect the flywheel for any damage such as scoring or excessive wear. If necessary, have the flywheel resurfaced by a professional machinist. Even if the release bearing looks fine, it’s a good idea to replace it during this process to ensure long-term reliability. Any bearing, bushing, or gasket that is accessed during the installation of Pagoda parts should be replaced regardless of condition. 

Step 5: Installing the New Clutch Disk 

Now that the old clutch is out, it’s time to install the new Clutch Disk for a 4 Speed Manual Transmission (0042501703). Be sure to compare the new disk with the old one to ensure they match in size and design. If you are replacing the pressure plate as well, this would be installed alongside the clutch disk. 

1. Align the clutch disk: Position the new clutch disk on the flywheel. Use a clutch alignment tool to ensure the disk is centered. This tool will make installation of the transmission easier later. 
2. Install the pressure plate: Place the new pressure plate over the clutch disk. Tighten the pressure plate bolts evenly in a crisscross pattern to avoid any uneven pressure that could warp the plate or misalign the clutch disk. 
3. Tighten to specification: Use a torque wrench to tighten the pressure plate bolts to the manufacturer’s recommended torque specification. Make sure to access the owner’s manual when replacing Pagoda parts to determine torque specification for tightening such parts.

Step 6: Replace the Release Bearing 

The release bearing, also known as the throw-out bearing, is a critical component of the clutch system. It is located on the clutch fork and is responsible for pressing against the pressure plate to disengage the clutch. 

1. Remove the old release bearing: Slide the old bearing off the clutch fork. 
2. Install the new release bearing: Apply a small amount of high-temperature grease to the bearing surface where it contacts the clutch fork, then slide the new bearing into place.

Step 7: Reinstall the Transmission 

With the new clutch disk and related components installed, it’s time to reinstall the transmission. This process is essentially the reverse of removal but requires attention to alignment. 

1. Align the transmission: Use the transmission jack to lift the transmission into place. Ensure the input shaft is correctly aligned with the clutch disk using the clutch alignment tool as a guide. 
2. Bolt the transmission in place: Once the transmission is properly aligned, bolt it back to the engine. Reattach the transmission cross-member and secure the mount. 
3. Reconnect linkages and wiring: Reconnect the shifter linkage and any electrical connections you removed earlier. 

Step 8: Reattach the Driveshaft 

With the transmission back in place, you can now reinstall the driveshaft. 

1. Reconnect the flex discs: Attach the flex disc at the rear of the transmission and the rear differential. Bolt everything securely, ensuring proper alignment. 
2. Install the center support bearing: Bolt the center support bearing back into place, ensuring the driveshaft is properly supported and aligned. Alignment is always key when installing Pagoda parts because a misaligned part may not operate properly or even worse, could lead to damage of other parts.

Step 9: Test and Adjust (should be done for all Pagoda parts replacements)

Before lowering the car, check your work to ensure that everything is properly tightened and connected. Once satisfied, lower the car from the jack stands. Reconnect the negative battery terminal, and start the car to test the clutch. Make sure the clutch engages smoothly and without noise. 

Conclusion 

Replacing Pagoda parts, like the Clutch Disk for a 4 Speed Manual Transmission (0042501703), requires patience and attention to detail. By following the steps outlined above, you can ensure the job is done correctly. With the new clutch installed, your 280 SL will once again offer the smooth, responsive driving experience that these classic roadsters are known for. Always remember to consult the vehicle’s service manual for torque specifications and additional details specific to your car’s model year.