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

2
 Features 722.9
h Electronically controlled 7-speed

h Seven forward and two reverse gears

h Fully integrated transmission control unit (Flash capable)

h Torque converter operates in open or slip mode in all seven

forward gears

h Gear ratios are achieved with four multi disc brakes and three
multi disc clutches (no free-wheeling units)

h 2 simple and 1 ravigneaux gear set

3
 Advantages
? Improved shift comfort/driving pleasure

q Quicker shifts 0.1 – 2.5 seconds

q 37 to 74 mph times shortened by between 23% and 28%

? Reduce fuel consumption (up to 4%)

? Reduce maintenance cost

h Increased service life and reliability

h Flexible adaptation to vehicle and engine

h 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
q Higher thermal stability
q Improved temperature behavior
q Lifetime fill

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

? Must be used in 722.9

6
Major Components (7 G-Tronic)

7
 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
8
 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. Short planetary gear
2. Long planetary gear
3. Sun gear
4. 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 1. Friction lining on one side of metal carrier

A. Metal carrier outer disk
B. Metal carrier inner disk
• Lower mass

11
Fully Integrated Transmission
Control

12
 Fully Integrated Transmission
Control Legend

11 Plug connection Y3/8y1 Working pressure control solenoid valve

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

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 Y3/8n1 Turbine rpm sensor

2. Cylinder flange with Y3/8n2 Internal rpm sensor
integrated ring magnet Y3/8n3 Output rpm sensor
3. Exciter ring
4a. Park pawl gear
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
Y3/8y8 – Torque converter lockup clutch valve
Y3/8y1 – Working pressure valve
• B2 brake valve (Y3/8y6) Y3/8y3 – K2 clutch valve
normally closed in default no Y3/8y6 – B2 brake valve
pressure

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) Y3/8y2 – K1 clutch valve

normally open in default allows Y3/8y5 – B1 brake valve
Y3/8y7 – B3 brake valve
pressure
Y3/8y4 – K3 clutch valve
23
 722.9
Down Shifting

24
Shift Chart

25
 7 Release B3

Apply B1 6 Release B1

Apply K1 5 Release K3

Apply B2 4 Release K2

Apply K3 3 Release K1

Apply B1 2 Release B1

Apply B3 1 26
Release B3
7

6 Release K2

Apply K1
5
Release K2

Apply B2
3
Release K1
Apply B2
2

Apply B3
1 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 Control Unit Version
q Fault Codes
q Freeze Frame Data
q Read Coding Page in Control Unit Adaptions Menu

? From ESM Control Unit

q Control Unit Version
q Fault Codes

? Must be original printouts!

q Photocopies will not be accepted
q 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 45°C when checking level
39
Prototype 7 G-Tronic Filling
Station

40
 Key Function Of Filling Station
iProvidean 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

i 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

i 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

i Shift through gear selections several

times to purge any air from
hydraulic system

i Program remaining portion of new

722.9 fluid (4 liters for dry fill) at
dispenser handle

i At approximately 30°C add remaining fluid

50
 Unit Operation
Preliminary Instructions
i At 30 - 35°C 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 35°C 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
53