722.

9 Automatic Transmission

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

Objectives
?

To know the advantages and Features of the

722.9 transmission

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
h

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
?

Improved shift comfort/driving pleasure

q

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

4

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
5

Transmission Fluid
?

The 722.9 transmission requires a newly developed transmission

fluid. MB part number A001 989 45 03
q

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
9

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

10

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

11

Fully Integrated Transmission

Control

12

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

13

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)

14

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

15

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

16

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
17

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
18

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

19

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

Fast release

The up-shift to the next gear is prevented and is

only allowed again at low lateral vehicle acceleration

Kick-down

Bringing forward and raising of the downshift

characteristic in the upper vehicle speed range
20

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

21

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

22

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

23

722.9
Down Shifting

24

Shift Chart

25

Release B3

Apply B1

Release B1

Apply K1

Release K3

Apply B2

Apply K3

Release K1

Apply B1

Release B1

Apply B3

Release K2

26

Release B3

7
6

Apply K1
Release K2

Release K2

5
4

Apply B2

3
Release K1

2
Apply B3

Apply B2

27

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

28

Special Tools

29

30

31

32

33

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

34

Diagnostics Via EDAC

35

Service Advisors Checklist

must be filled out before
repair attempt

36

Diagnostics Via EDAC

37

Information Needed for Warranty

?

From Transmission Control Unit

q
q
q
q

From ESM Control Unit

q
q

Control Unit Version

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

Control Unit Version

Fault Codes

Must be original printouts!

q
q

Photocopies will not be accepted

Do not erase fault codes

38

Transmission Oil Pan

Note: new oil pan soon available requires slightly different procedure for filling
Temp. must be 40 to 45C when checking level
39

Prototype 7 G-Tronic Filling

Station

40

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

41

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)

42

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)

43

Unit Operation
Preliminary Instructions
i

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)

44

Unit Operation
Preliminary Instructions

Connect unit to shop air supply - (no min. max. spec at present)
45

Unit Operation
Preliminary Instructions

Turn main valve on front panel to pressure position

46

Unit Operation
Preliminary Instructions

Turn main valve on front panel to pressure position

47

Unit Operation
Preliminary Instructions
i

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
48

Unit Operation
Preliminary Instructions
iConnect

SDS / DAS to view actual values

49

Unit Operation
Preliminary Instructions
i

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

50

Unit Operation
Preliminary Instructions
i

At 30 - 35C place Y-valve to drain back (vertical position)

iTurn

main valve to depressurize position on front panel

51

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

52

Questions

More to come
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