722.

9 Automatic Transmission

Tech 331, 722.9 (F,hayward),1/27/04

Objectives
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To know the advantages and Features of the 722.9 transmission

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To identify new components To understand maintenance concerns To know location / function of major components To explain shift members To explain electronics

Features 722.9
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Electronically controlled 7-speed Seven forward and two reverse gears Fully integrated transmission control unit (Flash capable) Torque converter operates in open or slip mode in all seven forward gears Gear ratios are achieved with four multi disc brakes and three multi disc clutches (no free-wheeling units) 2 simple and 1 ravigneaux gear set

Advantages
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Improved shift comfort/driving pleasure

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Quicker shifts 0.1 2.5 seconds 37 to 74 mph times shortened by between 23% and 28%

Reduce fuel consumption (up to 4%)

Reduce maintenance cost

Increased service life and reliability

Flexible adaptation to vehicle and engine

Driver can choose between S and C mode

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Transmission Designation
Transmission 722. 9 01
Version, e.g. matching to the respective engine Sales designation Automatic transmission for passenger cars

Sales Designation W 7 A 700

Max. input torque in NM Version (internal) Number of forward gears Hydraulic torque converter
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Transmission Fluid
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The 722.9 transmission requires a newly developed transmission fluid. MB part number A001 989 45 03
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Higher friction constancy Higher thermal stability Improved temperature behavior Lifetime fill

Can be used in 722.3 / .4 / .5 / .6

Must be used in 722.9

Major Components (7 G-Tronic)

Major Components Legend

1. Park pawl gear 2. Turbine wheel 3. Stator 4. Impeller 5. Transmission housing ventilation 6. Oil pump 7. B1 multi-disk brake 8. K1 multi-disk clutch 9. Ravigneaux gear set 10. B3 multi-disk brake 11. K2 multi-disk clutch 12a. Front simple planetary gear set 12b. Rear simple planetary gear set 13. BR multi-disk brake 14. K3 multi-disk clutch 15. B2 multi-disk brake 16. Torque converter lockup clutch 17. Torque converter housing 18. Exciter ring for torque measurement 19. Ring magnet for torque measurement 20. Ring magnet for torque measurement 21. Electro hydraulic control unit 22. Range selector lever

Transmission Housing

Magnesium housing (lighter weight) requires aluminum bolts any aluminum bolt must be replaced if removed! No power tools Adhere to angle torques
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Ravigneaux Gear Set

Advantages of ravigneaux gear set Shifting under load Production of several gear ratios Constant engagement of gearing Easier reversal of rotational direction High efficiency Compact construction Combines 2 simple planetary gear sets into one unit

1. 2. 3. 4.

Short planetary gear Long planetary gear Sun gear Planetary gear carrier

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Multi-disk Clutch/Brake
Transferable power of multi-disk clutch increased Friction disks of K1, K2 and K3 now have single-sided friction disks Cost advantage Less installation space required Higher load capability Lower mass 1. A. B. Friction lining on one side of metal carrier Metal carrier outer disk Metal carrier inner disk

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Fully Integrated Transmission Control

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Fully Integrated Transmission Control Legend

11 21b 21c 21d 31 32 Y3/8 Y3/8n1 Y3/8n2 Y3/8n3 Y3/8n4 Plug connection Valve body Intermediate panel Shift housing Float 1 Float 2 Electric control module Turbine rpm sensor Internal rpm sensor Output rpm sensor Transmission control unit Y3/8s1 Selection range sensor Y3/8y1 Y3/8y2 Y3/8y3 Y3/8y4 Y3/8y5 Y3/8y6 Y3/8y7 Y3/8y8 Working pressure control solenoid valve K1 clutch control solenoid valve K2 clutch control solenoid valve K3 clutch control solenoid valve B1 brake control solenoid valve B2 brake control solenoid valve B3 brake control solenoid valve Torque converter lockup clutch control solenoid valve

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Electronic Transmission Control Unit Inputs

Monitors and shifts transmission based on: Vehicle speed Vehicle load Accelerator position Selector lever position Electronic selector lever module (N15/5) Transmission condition (aging)

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Electronic Transmission Control Unit Inputs

Internal inputs effecting solenoid valves Turbine rpm sensor (active) Internal rpm sensor (active) Output rpm sensor (hall) Transmission oil temperature sensor

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Electronic Transmission Control Unit

Mounted directly on the hydraulic control unit Married to vehicle ETC unit calibrated to hydraulic control unit on flow bench Information received over CAN with ME Engine rpm, coolant temperature, accelerator position, engine load ESP signals Cruise control signals Information received from ETC Position of selector range valve Transmission oil temperature Transmission internal revolutions Transmission output rpm

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Electronic Transmission Control Unit Functions

From data received Transmission control unit calculates Driver and vehicle specific shift points Hydraulic pressures Torque converter lockup clutch Corrects for atmospheric pressure, shifting and pressure Driver actions; accelerator movement, manual touch frequency, longitudinal and lateral acceleration Software can be updated, referred to as flashing, carried out using SDS
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Speed Sensor Locations

Turbine speed sensor monitors rotational speed of internal ravigneaux gear Internal speed sensor measures rotational speed front planetary gear Output speed sensor measures transmission output speed park pawl Output speed sensor increases reaction time

1. Ring magnet 2. Cylinder flange with integrated ring magnet 3. Exciter ring 4a. Park pawl gear

Y3/8n1 Y3/8n2 Y3/8n3

Turbine rpm sensor Internal rpm sensor Output rpm sensor

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Shift Program
Basic shift program can be influenced using selector button on the electronic selector lever control module Driver can choose transmission modes, C (comfort) or S (sport) Each mode has different shift strategies Transmission mode S (firmer faster shift) as opposed to mode C engine rpm level raised Switch position transmitted by electronic selector module over CAN-C to ETC

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Shift Programs
The adjustment of the shift programs takes place by moving the characteristic dependent on: Vehicle payload Change in engine load Pedal movement Slow Unintended downshifts in high vehicle speed range are prevented The up-shift to the next gear is prevented and is only allowed again at low lateral vehicle acceleration Bringing forward and raising of the downshift characteristic in the upper vehicle speed range
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Fast release

Kick-down

Shifting Process
ETC controls solenoid valves electronically Valves sit in hydraulic shift plate Shift plate implements hydraulic function ETC precisely adjusts pressure during shift phase, which leads to increase in shift quality Main function of ETC is to evaluate inputs relevant to transmission function and actuate eight hydraulic valves, which set working pressure

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Solenoid Valves
Internal output signal or actuation of control solenoid valves Torque converter lockup clutch valve (Y3/8y8) normally closed in default no pressure Working pressure valve (Y3/8y1) normally open in default allows pressure K2 clutch valve (Y3/8y3) normally open in default allows pressure B2 brake valve (Y3/8y6) normally closed in default no pressure
Y3/8y8 Torque converter lockup clutch valve Y3/8y1 Working pressure valve Y3/8y3 K2 clutch valve Y3/8y6 B2 brake valve

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Solenoid Valves
Internal output signal or actuation of control solenoid valves K1 clutch valve (Y3/8y2) normally open in default allows pressure B1 brake valve (Y3/8y5) normally open in default allows pressure B3 brake valve (Y3/8y7) normally closed in default no pressure K3 clutch valve (Y3/8y4) normally open in default allows pressure
Y3/8y2 Y3/8y5 Y3/8y7 Y3/8y4 K1 clutch valve B1 brake valve B3 brake valve K3 clutch valve

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722.9 Down Shifting

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Shift Chart

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7
Apply B1

Release B3

6 5 4 3 2 1

Release B1

Apply K1

Release K3

Apply B2 Apply K3

Release K2 Release K1

Apply B1

Release B1

Apply B3

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Release B3

7 6

Release K2

Apply K1 Release K2

5 4

Apply B2

3
Release K1

2
Apply B3

Apply B2

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Emergency Function
To guarantee safe driving and prevent damage ETC switches to emergency mode on critical faults Electric fault, all control solenoid valves switched off, transmission enters emergency mode defaults to 6th gear After engaging P, D provides 2nd gear and reverse Hydraulic faults engaged gear is kept Solenoid valve faults effected gear is blocked no longer actuated Flat bed transportation recommended (vehicle not drive-able) If towing must be performed max. towing speed 31 mph max. distance 31 miles, no lubrication pressure

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Special Tools

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Process Overview for Repair Work

Dealer verifies customer report related to Transmission Diagnose condition via Diagnosis Guide posted on STAR Tekinfo website Dealer contacts EDAC if it is determined that there is an actual issue requiring assistance EDAC reviews diagnosis including completeness of MBUSA provided diagnostic information EDAC Authorized replacement of necessary components Dealer returns authorized component with EDAC authorization number referenced in the DTC field of the warranty claim or handling fee will be debited

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Diagnostics Via EDAC

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Service Advisors Checklist must be filled out before repair attempt

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Diagnostics Via EDAC

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Information Needed for Warranty

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From Transmission Control Unit

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Control Unit Version Fault Codes Freeze Frame Data Read Coding Page in Control Unit Adaptions Menu

From ESM Control Unit

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Control Unit Version Fault Codes

Must be original printouts!

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Photocopies will not be accepted Do not erase fault codes

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Transmission Oil Pan

Note: new oil pan soon available requires slightly different procedure for filling Temp. must be 40 to 45C when checking level
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Prototype 7 G-Tronic Filling Station

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Key Function Of Filling Station

iProvide

an accurate method to fill 722.9 after service has been performed that will still be time and cost effective

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Unit Operation Preliminary Instructions

Raise vehicle and remove drain plug Use caution as some fluid will spill, the converter drains back with engine shut off Using special tool no. 722-589-03-15-00 remove plastic pipe if replacing transmission discard old fluid if servicing transmission save and measure fluid content for refill Remove six aluminum torque to yield screws part no. A 004-990-35-12 and discard, New screws must be used! Remove pan inspect and clean Replace plastic overflow pipe onto pan Install pan using six new aluminum torque to yield screws Torque to 4nm. + 180 (See WIS)
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Unit Operation Preliminary Instructions

Screw adapter interface fitting part no. ??? into pan drain / fill port Attach Y - valve and manifold to interface adapter (valve handle in horizontal position)

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Unit Operation Preliminary Instructions

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Check fluid level in fresh fluid tank there is a sight glass in lower cabinet rear

Add new 722.9 fluid as necessary 30 liter max capacity (replace cap on fresh fluid tank)

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Unit Operation Preliminary Instructions

Connect unit to shop air supply - (no min. max. spec at present)
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Unit Operation Preliminary Instructions

Turn main valve on front panel to pressure position

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Unit Operation Preliminary Instructions

Turn main valve on front panel to pressure position

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Unit Operation Preliminary Instructions

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Program dispenser handle to auto. set to number of liters desired squeeze handle and release, it will dispense automatically, you can stop flow by pressing the red button on the handle You can also dispense manually by simply squeezing the handle, Batch will count up on LCD useful for service refill - top off the fill

NEW UNIT DRY FILL = 6 LITERS AT THIS POINT REFER TO WIS

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Unit Operation Preliminary Instructions

iConnect

SDS / DAS to view actual values

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Unit Operation Preliminary Instructions

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Making certain no hoses are close to exhaust start and idle engine Shift through gear selections several times to purge any air from hydraulic system Program remaining portion of new 722.9 fluid (4 liters for dry fill) at dispenser handle At approximately 30C add remaining fluid

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Unit Operation Preliminary Instructions

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At 30 - 35C place Y-valve to drain back (vertical position) main valve to depressurize position on front panel

iTurn

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Unit Operation Preliminary Instructions

As drain back stops at 35C remove Y-valve and interface
adapter fitting from pan Fluid level is now correct performing this operation at any other temperature will result in an incorrect fluid level Install drain / fill plug Wipe any residual fluid from pan Check for leaks Replace any brackets and or under body encapsulation panels that may have been removed during this service operation

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Questions

More to come
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