I have a friend that is helping me change out the blower motor in my 1980 240 GL, but he has only changed out 84 and above. My question is, is there any difference; and is there anything we should look out for?
Thanks,
Joe

Do a search on the blower motor replacement by Art Benstein or others, there are detailed pics of the whole operation that are VERY usefull. Good luck cause it can be some what of a pain be sure to remove the dash, a 15 minute addition to get a lot better access to the housing..
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Max..1989 244 DL 5 Spd., Bilstein HD, Turbo Swaybars, Poly Bushings all round, Turbo Wheels, Black leather interior, Electric mirrors, LED dash and gauge lights. 1989 Maroon 244 auto tranny, totally stock. 1992 black 244 auto tranny, next project.

You'll have to grind down the housing for the new motor.

The old motor wasn't round like the new one will be.

Use a dremel tool or something similar, and be sure to cover the heater core to prevent plastic chips from falling in there.

Vacuum everything very thoroughly when you are done.

Other then that it's about the same.

Also, you'll have to find a place to put the resistor, since your old motor doesn't have that big pack like the new set up will. I just had the resistor held in place with one of the 3 motor mounting screws when I did the task in my '80 245 DL. (I used the highest screw to be specific.) I did have to file out a little notch in the plastic surround that holds the motor in place. Just make sure you keep the resistor pack INSIDE the housing, and not out side. That thing gets very hot, and it will bake if it's not inside the housing where there is airflow to cool it down.

Good luck. It's one hell of a job, that's for sure. You owe your friend a HUGE favor. Heh heh heh...
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If you listen to the radio in Portland, OR, you may know me as 'Portland's Favorite Soul Brother!'