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Thread: Build and Restoration: 1994 S124 w/ 600hp OM606, 5-speed standard trans

  1. #1
    Junior Member S70/2's Avatar
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    Build and Restoration: 1994 S124 w/ 600hp OM606, 5-speed standard trans

    I am building this car for member viking1, it is nearing completion and I thought it was good time for a build thread.

    Quick run down :

    Car:
    Rust and accident free 1994 S124 E320 Green on Tan - 225,000 happy gasoline powered miles
    Sold at Beverly hills MB and came with original window sticker

    Motor:
    -1999 OM606.962 - Horsepower goal is 600+RWHP 700+TQ and 3.5+Bar of boost
    -DieselMeken 8mm pump
    -Precision PT6466 Dual Ceramic Ball Bearing Turbo V-band in/outlets
    -Precision PW46 Wastegate 21psi springs for "low" boost
    -Full 3" stainless exhaust
    -AEM Methanol Injection with 2.5 Gallon tank
    -Bosch 044 fuel pump
    -Aeromotive adjustable FPR set to 15psi
    -Water to Air intercooler with dual heat exchangers mounted on either side of the bumper
    -5 Gallon tank with Bosch Cobra water pump
    -Air Conditioning!

    Transmssion:
    -BMW ZF320 5 speed from E36 M3 (Known for taking lots of abuse in turbo E36s)
    -Diesel pump UK ZF adapter
    -DPUK Clutch and flywheel
    -E34 M5 765 Sachs Pressure plate and Disc
    -Custom E46 Shift arm and Selector rod
    -Custom Cross brace
    -W201/124 Manual Pedal box
    -M104 Driveshaft lengthened 45mm
    -WaveTrac LSD 2.65
    -Rebuilt Axles

    Suspension:
    -Bilstein HD front struts with new mounts
    -All new steering components
    -Lorinser lowering springs
    -New wheel bearings front and rear
    -New front control arms
    -New Front and Rear Subframe bushings
    -New Diff Mounts
    -All new rear links
    -LCA Bushings inner/outer
    -SLS delete with rear air shocks

    Brakes:
    -R129 Silver Arrow Brembos Front and Rear (Thanks GSXR!)
    -Goodridge stainless brake lines
    -ATE Type 200 Fluid

    Wheels:
    -18x8 - 18x9 / ET31 - 35 E55 Monoblocks, freshly refinished in silver with machined lips
    -Potenza RE-71Rs

    Body:
    -Full AMG body kit, the car came with genuine side skirts and rear bumper already installed. Need to source a matching front bumper


    I am organizing all the pictures now, I will post them in a little while
    Last edited by S70/2; 05-11-2017 at 09:11 PM.

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  3. #2
    .036 Hoonigan™
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    Re: 1994 S124 OM606 5SPD STD Build and Restoration

    Awesome - glad to have you (and Blair) here. Welcome to the forum, and keep the info & photos coming!

    Dave M.
    1997 E420 (Bugeyes)
    1994 E420 (Blondie)
    1994 E500 (Q-ship)
    1992 500E (Mach 5)
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  5. #3
    Junior Member S70/2's Avatar
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    Re: Build and Restoration: 1994 S124 w/ 600hp OM606, 5-speed standard trans

    Here is the car a few days after he got it, it came with the staggered AMG wheels pictured in addition to the AMG side skirts/bumper and Lorinser springs.



    Test fitting E55 Monoblocks after refinishing



    Goodbye M104, your soy ETA will not be missed



    In need of a good cleaning



    Mounted RE-71Rs



    OM603 PS pump rebuild



    The oil pan gasket was fused to the pan, needed aircraft paint stripper to safely remove it. A whole day of gasket removal



    Much better





    Turbo feed and return lines





    Slightly better than a tired 722.3







    Dropped in without too much fuss



    Getting an idea for the trans brace





    I used a E46 330i shifter arm and selector rod, needed to add about 75mm to both and put a slight CCW rotation also to compensate for the angle of the ZF.






    Lots more pictures coming
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  7. #4
    Junior Member S70/2's Avatar
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    Re: Build and Restoration: 1994 S124 w/ 600hp OM606, 5-speed standard trans

    Ok lets talk about diesel conversion wiring, my goal was to make it as clean and factory as possible.

    Here is the modified NSS harness, now with ZF reverse light plug and OM603 ring gear speed sensor. Starter wires are looped



    Diesel tachometer harness, this runs down and connects in the stock location inside the driver foot well for the NSS.



    Temp sender wire removed from stock 4 pole connector and modified to plug into glow harness



    Redone Oil pressure, level, and start harness. Look at that soy



    For the 400e digital speedo, I retained the V8 4 pole connector. The power and ground from the M104 can be moved into it and only one extra wire (signal) is needed. This will run to the dakota digital converter box





    This is the stock 2 pin speedo connector for cable drive



    Finished Cluster. 400e Speedo, OM603 Tach, WTS panel light



    Laid out before install
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  9. #5
    Junior Member S70/2's Avatar
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    Re: Build and Restoration: 1994 S124 w/ 600hp OM606, 5-speed standard trans

    I modified the stock throttle cable end to work with the DPUK cable/bracket. Just needed a little filing and the screw barrel fit nicely.





    With the plastic firewall plug installed



    Manual pedal box, new master cylinder and bushings



    This makes my back hurt just looking at it again



    Since the MC thread is larger than the BMW, I converted both the master and slave to -3AN and used a 30" premade SS hose. It worked great and ended up costing less than just the OEM mercedes hard line


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  11. #6
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    Re: Build and Restoration: 1994 S124 w/ 600hp OM606, 5-speed standard trans

    Front suspension looking good




    Slight difference



    Here is the method I used to remove the rear/rear subframe bushings. Worked well and took about 10 minutes per side to remove
    First drill out the center



    Then deform the edge with a hammer and punch



    Then simply pop it out



    Not a lot of fun



    The rear/fronts came out in two pieces and leaked out some terrible smelling oil



    Made a puller for the LCA bearings, still a ton of work to get them out. I ended up removing the centers, then tig welding the race in multiple spots to shrink it





    Finally empty rear knuckles ready for paint and bearings
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  13. #7
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    Re: Build and Restoration: 1994 S124 w/ 600hp OM606, 5-speed standard trans

    3" stainless downpipe ready for welding


    Getting an idea of how the intercooler is going to sit, not much room to work with but it will all squeeze in


    Just enough space


    Here you can see how the charge piping will run. All the wiring, cooling system, oil lines, AC system, and fuel lines are hooked up and still a good amount of space for extras
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  15. #8
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    Re: Build and Restoration: 1994 S124 w/ 600hp OM606, 5-speed standard trans

    The AC was more of a challenge than I originally anticipated. I had hoped the M104 compressor would share a bolt pattern with either a 603 or 606 compressor. This was not the case.

    M104 on top - OM603 on bottom , similar but different in every way






    The solution was to use a OM603 compressor, with bracket and hard lines. Now of course the early and late condenser connections are totally different also. I ended up combining the early/late Hi-side line with crimper

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    Re: Build and Restoration: 1994 S124 w/ 600hp OM606, 5-speed standard trans

    Awesome project! Subscribed
    '94 E500 (744) | '94 E500 (199)         Misc. snapshots

  18. #10
    Senior Member Allgonquin's Avatar
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    Re: Build and Restoration: 1994 S124 w/ 600hp OM606, 5-speed standard trans

    There is much awesomeness here.
    Allgonquin

    Objects in closer are mirror than they appear

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    Re: Build and Restoration: 1994 S124 w/ 600hp OM606, 5-speed standard trans

    Did you extend the driveshaft yourself or have a shop do the job? Just curious how they were able to extend it and keep the pieces balanced?
    1995 E36 wagon

  20. #12
    Junior Member S70/2's Avatar
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    Re: Build and Restoration: 1994 S124 w/ 600hp OM606, 5-speed standard trans

    Quote Originally Posted by ccrelan View Post
    Did you extend the driveshaft yourself or have a shop do the job? Just curious how they were able to extend it and keep the pieces balanced?

    I had AZ driveshaft extend and rebuild/balance it. They also installed the wavetrac and resealed the diff. Haven't gotten either back yet, but should next week hopefully.

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  22. #13
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    Re: Build and Restoration: 1994 S124 w/ 600hp OM606, 5-speed standard trans

    Did I miss it? Are you going to use a V8 diff over the original?

    Neat stuff- load wise it maybe small, but if you have service issues with cracking- got some suggestions to improve the rear trans mounting bracket. Just PM me.

    For the a/c lines, you can go to some free-form. Just need standard barb ends welded on and then cut to length the barrier hose and install with a portable crimping tool.

    M

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  24. #14
    Junior Member S70/2's Avatar
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    Re: Build and Restoration: 1994 S124 w/ 600hp OM606, 5-speed standard trans

    Using the standard 2.65 210mm Non-ASR diff with the wavetrac. Does anyone know if non-asr V8 (early 91-92 R129?) output flanges are compatible with the smaller axle flange 210mm diff?

    The AC line just needed a double ended barb and the crimp sleeves, no big deal with the crimp tool.

  25. #15
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    Re: Build and Restoration: 1994 S124 w/ 600hp OM606, 5-speed standard trans

    Quote Originally Posted by S70/2 View Post
    Using the standard 2.65 210mm Non-ASR diff with the wavetrac. Does anyone know if non-asr V8 (early 91-92 R129?) output flanges are compatible with the smaller axle flange 210mm diff? .
    The early R129 (129.066 only) shares the same diff housing as the 400E and 500E (ASR and non-ASR are different of course). I believe the flanges are interchangeable between non-ASR diffs, the problem you may run into is the flanges may not match the axle shaft CV joint. I believe he V8 uses larger bolts (M12 vs M10?). You may need to experiment with different axle shafts to get things matched up. I'm hoping the axle shaft length won't be an issue. You may be able to use 400E axles and non-ASR flanges. If so, you may want to source 400E ASR axles (or, 500E axles) as the axle shaft diameter is larger; 32mm ASR vs 25mm non-ASR... and with the 606 torque you'll need the beefiest stuff you can fit back there.


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    Re: Build and Restoration: 1994 S124 w/ 600hp OM606, 5-speed standard trans

    Luckily we already have a set of 400e ASR CV axles, and the matching stub axles/bearing carriers. The driveline shop said that the V8 bearing carriers/stubs can't be used with the non-asr diff due to the spline diameter being larger.

    Is it possible to put a wavetrac into a ASR V8 Diff? If so, it doesn't make any sense about the spline diameter being different. Unless they sell two separate units...
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    Re: Build and Restoration: 1994 S124 w/ 600hp OM606, 5-speed standard trans

    Quote Originally Posted by S70/2 View Post
    Luckily we already have a set of 400e ASR CV axles, and the matching stub axles/bearing carriers. The driveline shop said that the V8 bearing carriers/stubs can't be used with the non-asr diff due to the spline diameter being larger.
    That makes no sense. The ASR flanges / stubs are different, as they have the rotors for the ASR speed sensors, but the splines into the diff are the same.


    Quote Originally Posted by S70/2 View Post
    Is it possible to put a wavetrac into a ASR V8 Diff? If so, it doesn't make any sense about the spline diameter being different. Unless they sell two separate units...
    Absolutely, yes, many people have done this. The differential itself is the same for ASR and non-ASR. Only the housing is different (sensors in different locations), and the axle flanges/stubs as mentioned above.

    Dave M.
    1997 E420 (Bugeyes)
    1994 E420 (Blondie)
    1994 E500 (Q-ship)
    1992 500E (Mach 5)
    1987 300D (Sportline Stage 2)
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  31. #18
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    Re: Build and Restoration: 1994 S124 w/ 600hp OM606, 5-speed standard trans

    I am only paraphrasing here as Blair has been dealing directly with the shop. But now I am thinking what they meant is that the ASR bearing carriers are thicker than non-ASR and the spacing will will be incorrect due to the difference in the cases.

    Non-ASR V8 carriers/stubs/CVs should be the solution.

    Looking at early non-asr 500sl axles they appear to use the large CVs/stubs but then the small 25mm diameter axle shaft. So hopefully ASR axles will fit even though the length is about 10-15mm longer.

    I am going to open up the ends and see what the size difference of the splines are in the CVs
    Last edited by S70/2; 05-11-2017 at 02:22 PM.

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  33. #19
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    Re: Build and Restoration: 1994 S124 w/ 600hp OM606, 5-speed standard trans

    As I suspected the splines are the same size, however the ASR axles are 30mm from shoulder to circlip base and the non-ASR are only 26mm.

    So it would be possible to use the small CVs on the large diameter axles with a 4mm spacer. The wheel side CV appears to be the same between them, which may ultimately be the weakest point.
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    Re: Build and Restoration: 1994 S124 w/ 600hp OM606, 5-speed standard trans

    Amazing

  36. #21
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    Re: Build and Restoration: 1994 S124 w/ 600hp OM606, 5-speed standard trans

    So the outer CV is the same size on both, identical to the M104 inner. Also uses 26mm spline depth.
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  38. #22
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    Re: Build and Restoration: 1994 S124 w/ 600hp OM606, 5-speed standard trans

    Is the V8 inner CV (at the diff) larger / stronger than the M104 inner CV? Size, bolt diameter, CV diameter, etc? I've never had one of each loose to compare.


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  40. #23
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    Re: Build and Restoration: 1994 S124 w/ 600hp OM606, 5-speed standard trans

    Quote Originally Posted by gsxr View Post
    Is the V8 inner CV (at the diff) larger / stronger than the M104 inner CV? Size, bolt diameter, CV diameter, etc? I've never had one of each loose to compare.


    Everything about the V8 Inners are beefier. Bigger bolt diameter, larger ball cage, thicker center star with 30mm spline depth.

    V8 on left - M104 on right
    image.jpg


    V8 outer - M104 inner - V8 Inner
    image.jpg

    So upgrading to the V8 inners may be a moot point if the outers can't take the torque.

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  42. #24
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    Re: Build and Restoration: 1994 S124 w/ 600hp OM606, 5-speed standard trans

    Awesome info - confirms what I suspected, thanks!

    I blew up the inner CV of a W210.072 joint at the dragstrip last summer. I believe the 210 CV's are the smaller / weaker size similar to the M104. Good to know you can use stronger V8 bits for the Uberwagen.


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    Re: Build and Restoration: 1994 S124 w/ 600hp OM606, 5-speed standard trans

    This is so tasty
    1979 450SLC 5.0 :1980 280GE SWB 4MT
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    1986 190E 2.3-16 5MT : 1990 500SL AMG 6.0
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    Re: Build and Restoration: 1994 S124 w/ 600hp OM606, 5-speed standard trans

    Amazing build!
    _____________________
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    Re: Build and Restoration: 1994 S124 w/ 600hp OM606, 5-speed standard trans

    Bosch 044 fuel pump
    image.jpg

    Ran a hot bath for the rear knuckles
    image.jpg image.jpg

    Installed LCAs and Wheel bearings, I'll tape everything off well then give them a coat of VHT epoxy satin black.
    image.jpg

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    Re: Build and Restoration: 1994 S124 w/ 600hp OM606, 5-speed standard trans

    Quote Originally Posted by S70/2 View Post

    Made a puller for the LCA bearings, still a ton of work to get them out. I ended up removing the centers, then tig welding the race in multiple spots to shrink
    Works best if you go all the way around, even adding filler metal. This works a treat !

    Sent from my SM-G900V using Tapatalk
    Last edited by 7delta; 05-13-2017 at 02:40 PM.
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  52. #29
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    Re: Build and Restoration: 1994 S124 w/ 600hp OM606, 5-speed standard trans

    Great project, always wanted to do a w124 superturbo build myself. Please keep the updates coming
    1987 w124 200 E36 AMG Project car - ongoing
    1990 w124 300E-24 Fully Restored
    1992 w124 500E Rolling Restoration - ongoing
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  53. #30
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    Re: Build and Restoration: 1994 S124 w/ 600hp OM606, 5-speed standard trans

    Small update, still waiting for the LSD and DS

    Got the rest of the rear end together, rebuilding the axles today.

    image.jpg


    image.jpg


    image.jpg

    image.jpg




    image.jpg

    Interested to see how the air shocks work out, retaining SLS is not very difficult on a 603/606 swap since you can just use a 87 300TDT pump
    image.jpg

    image.jpg


    All the charge piping is in place now, need one more 90 mandrel and it can be welded together to get rid of the silicon couplers
    image.jpg
    image.jpg

    Water outlet
    image.jpg

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  55. #31
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    Re: Build and Restoration: 1994 S124 w/ 600hp OM606, 5-speed standard trans

    image.jpg

    The hood actually closes luckily
    image.jpg

    S54 that had its 1400psi vanos oil line rupture and lost 6 quarts of oil in 15 seconds all over the engine bay

    image.jpg

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  57. #32
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    Re: Build and Restoration: 1994 S124 w/ 600hp OM606, 5-speed standard trans

    Alright more progress, got the entire rear end back together with rebuilt axles and wave trac LSD.

    image.jpg
    image.jpg

    Extended driveshaft fits like a glove to the ZF320 using OEM mercedes flex discs

    image.jpg


    Bosch cobra intercooler pump mounted in stock HP fuel pump location

    image.jpg




    Need to get an aluminum panel made for the gauges, until than cardboard mockup will suffice. I feel things like intercooler water temp and EGT readings are much more valuable to the passenger than a silly airbag.


    image.jpg


    Hallman manual boost controller, this will be cabin adjustable with a knurled aluminum knob


    image.jpg


    Bulk head AN fittings in the stock SLS sphere holes for the intercooler water lines running up to the 5 gallon tank

    image.jpg

    image.jpg

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    Weighted ZHP shit knob

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    Derale 2 speed 1800/2400 CFM fan just barely fit

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    Intercooler radiators mounted...just enough room to fit these without any body modifications. The entire core is also open to full air flow with the stock bumper cover

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    Also had the joy of doing an evaporator replacement on a 92 300d...it was not all that bad. Although the 110 ambient garage temps were less than ideal.

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    Last edited by S70/2; 1 Week Ago at 01:08 PM.

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  59. #33
    Junior Member S70/2's Avatar
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    Re: Build and Restoration: 1994 S124 w/ 600hp OM606, 5-speed standard trans

    Got the water lines in place and tested the pump today, flows nicely even with the 40+ft of hose. Just need a skid plate for them. Looks like the total capacity of the system is going to be 7.5+ gallons

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    This is the return

    image.jpg

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