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INDEX

Copyright © ATSG  2009

M E R C E D E S , J A G U A R ,

D A I M L E R / C H RY S L E R

" 7 2 2 . 6 "  " 5 S p e e d "

AUTOMATIC TRANSMISSION SERVICE GROUP

18635  S.W. 107  AVENUE

CUTLER BAY, FLORIDA  33157

(305) 670-4161

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TRANSMISSION IDENTIFICATION .........................................................................................
GENERAL DESCRIPTION ..........................................................................................................
INTERNAL COMPONENT IDENTIFICATION AND LOCATIONS .......................................
SOLENOID APPLICATION CHART ..........................................................................................
FLUID REQUIREMENTS AND CHECKING PROCEDURE ...................................................
OIL LEVEL CONTROL ................................................................................................................
SOLENOID LOCATIONS AND IDENTIFICATION .................................................................
SOLENOID OPERATION ............................................................................................................
ELECTRICAL CONDUCTOR PLATE ........................................................................................
CASE CONNECTOR TERMINAL IDENTIFICATION .............................................................
PARK/NEUTRAL CONTACT AND FLUID TEMP SENSOR ....................................................
N2 AND N3 INPUT SPEED SENSORS .......................................................................................
TRANSMISSION CONTROL MODULE AND LOCATIONS ....................................................
TCM CONNECTORS AND TERMINAL IDENTIFICATION ...................................................
SOLENOID RESISTANCE CHART ............................................................................................
SHIFT LEVER ASSEMBLY .........................................................................................................
TRANSMISSION RANGE RECOGNITION SWITCH ...............................................................
WIRING SCHEMATICS ...............................................................................................................
DIAGNOSTIC TROUBLE CODE DESCRIPTION ....................................................................
TORQUE CONVERTER OPERATION .......................................................................................
CHECKBALL AND SMALL PARTS LOCATIONS ....................................................................
HYDRAULIC PASSAGE IDENTIFICATION .............................................................................
F-1 AND F-2 FREEWHEEL DIRECTIONS ...............................................................................
TRANSMISSION DISASSEMBLY ..............................................................................................
COMPONENT REBUILD
        TRANSMISSION CASE ASSEMBLY ..................................................................................
        CONVERTER HOUSING, OIL PUMP AND B-1 CLUTCH ASSEMBLY .........................
        K-1 CLUTCH HOUSING ASSEMBLY (INCLUDES F-1 SPRAG) ....................................
        K-2 CLUTCH HOUSING ASSEMBLY ................................................................................
        GEARTRAIN IDENTIFICATION AND POSSIBLE TOOTH COUNTS ...........................
        CENTER AND REAR PLANETARY GEARTRAIN ASSEMBLY (INCLUDES F-2) .......
        K-3 CLUTCH HOUSING ASSEMBLY ................................................................................
        B-2 CLUTCH HOUSING ASSEMBLY ................................................................................
        VALVE BODY ASSEMBLY ..................................................................................................
TRANSMISSION FINAL ASSEMBLY ........................................................................................
TORQUE SPECIFICATIONS ......................................................................................................

Note: An "Update Handbook" with the familiar Green cover, is also available from ATSG 
and includes much more information on the valve body variations that are found in the 
722.6 transmission.

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Summary of Contents for 722.6

Page 1: ...ND TERMINALIDENTIFICATION SOLENOID RESISTANCECHART SHIFT LEVERASSEMBLY TRANSMISSION RANGERECOGNITION SWITCH WIRING SCHEMATICS DIAGNOSTIC TROUBLECODEDESCRIPTION TORQUE CONVERTEROPERATION CHECKBALLAND S...

Page 2: ...ay be reproduced stored in any retrieval system or transmitted in any form or by any means including but not limited to electronic mechanical photocopying recording or otherwise without written permis...

Page 3: ...here are currently four different planetarygearratios used in the722 6 unit NAG1 identifies a family of transmissions and means N ew A utomatic G earbox generation 1 Various marketing names are associ...

Page 4: ...5 210 082 210 265 210 282 210 072 210 070 210 070 210 083 111 974 ME 2 1 111 975 ME 2 1 112 912 ME 2 8 104 941 HFM 112 920 ME 2 0 112 946 ME 2 8 104 941 HFM 113 944 ME 2 0 119 980 ME 1 0 119 960 ME 2...

Page 5: ...6 722 6 722 632 722 620 722 620 622 722 6 722 6 722 621 722 621 722 621 722 628 722 603 5 722 620 722 620 624 722 621 32 722 605 722 616 722 616 722 618 722 618 722 6 JF74 GA32 GA33 GA32 NG70 NG70 GA...

Page 6: ...8 Engine CLK55 AMG Coupe 5 5L 24 Valve V 8 Engine CLK55 AMG Cabriolet 5 5L 24 Valve V 8 Engine CL500 Coupe 5 0L 24 Valve V 8 Engine CL55 AMG Coupe 5 5L 24 Valve V 8 Engine CL600 Coupe 5 5L 36 Valve V...

Page 7: ...nging gear ratios is fully automatic and is accomplished on the Mercedes units with the use of an Electronic Transmission Controller ETC On the Daimler Chrysler units it is referred to as a Transmissi...

Page 8: ...Hold Hold Hold 3 Hold Hold D 2nd D 3rd D 4th D 5th 1 Mode SelectorSwitchinthe S position 2 ModeSelectorSwitchinthe W position 3 Shiftcomponentsrequiredforenginebrakingduringcoastconditions TCCisavail...

Page 9: ...the gear the transmission failsafes to When the vehicle is brought to a stop and the ignition is cycled the transmission will remain in second gear Special Note If codes are stored and repairs havebe...

Page 10: ...til fully seated wait 3 seconds then remove the dip stick and check the fluid level indication on the dipstick asshown below Dipstick tool for Sprinter Crossfire use MillerTool 8863A Magnum 300C use M...

Page 11: ...h the bottom case opening When the oil level rises as fluid is heated the oil presses the float against the opening The float therefore seperates the transmission sump from the gearset chamber The lub...

Page 12: ...of the 722 6 transmission use a total of six solenoids mounted on the electronic conductor plate and the valve body as shown in Figure 10 The solenoids are located under 2 white plastic covers also sh...

Page 13: ...in order to ramp the converter clutch on and off making for a smooth converter clutch apply and release When the solenoid is at maximum exhaust the converter clutch is released When solenoid is at min...

Page 14: ...Exhaust Screen Screen Maximum Exhaust SHIFT PRESSURE CONTROL SPC SOLENOID OPERATION MINIMUM LINE RISE MAXIMUM LINE RISE From Regulating Pressure Control Valve From Regulating Pressure Control Valve To...

Page 15: ...alve To Lock up Control Valve Maximum Exhaust Figure 14 TORQUE CONVERTER CLUTCH PWM SOLENOID OPERATION From Shift Valve Pressure Control Valve To Shift Command Valve SOLENOID ON X Exhaust Blocked SOLE...

Page 16: ...al components to 13 way connector With the exception of the six solenoids all other electronic components are integrated and part of the electricalconductorplate SeeFigure15 MERCEDES BENZ A 140 27 0 0...

Page 17: ...ply Voltage For All Solenoids Sensor 5V Supply Voltage 2 3 Shift Solenoid Ground Control 3 4 Shift Solenoid Ground Control Shift Pressure Control Solenoid Ground Control TCC Solenoid Ground Control Se...

Page 18: ...the Park Neutral contact is closed when in Reverse or a forward gear position In Park or Neutral the TCM uses engine temperature to avoid setting a DTC Refer to the chart in Figure 18 to check theTFTu...

Page 19: ...shown in Figure 19 The speed sensors are Hall Effect speed sensors that are used by the TCM to calculate the transmissions input speed Since the input speed could not be measured directly two of the d...

Page 20: ...e TCM continuously checks for electrical concerns mechanical concerns and some hydraulic concerns When a transmission concern is detected the TCM stores a Diagnostic Trouble Code DTC Some of these cod...

Page 21: ...CHECKS Electrical and resistance checks can be easily as the TCM is located in one of five areas as shown in Figure 21 The only one that is troubling for the technician is the one in the Sprinter whi...

Page 22: ...nsmission Range Recognition Switch Data B 96 99 Only 2000 Up They use CAN bus Transmission Range Recognition Switch Data C 96 99 Only 2000 Up They use CAN bus Transmission Range Recognition Switch Dat...

Page 23: ...Component 14 38 15 38 16 38 17 38 36 38 37 38 13 34 6 13 6 9 6 8 6 11 6 2 6 10 4 7 2 5 6 5 Ohms 2 5 6 5 Ohms 2 5 6 5 Ohms 2 0 4 0 Ohms 2 5 6 5 Ohms 2 5 6 5 Ohms See Chart Figure 18 Pin 1 2 3 4 5 6 7...

Page 24: ...e passing by depressing the accelerator or by manually selectingalowergearwiththeshiftlever In this position the Driver has the option to push the lever to the left or to the right To the right would...

Page 25: ...eventing the vehicle from moving For safety reasons the vehicle s parking brake should always be usedinadditionto the Park position P SHIFT QUADRANTS CONT D Standard Shift Quadrant Cont d Limp Mode Op...

Page 26: ...ognition Switch TRRS With the face plate removed the TRRS circuit board can be easily seen This circuit board has attached to it wires which run to a connector in the rear of the assembly Shown in Fig...

Page 27: ...HFT SOL 3 4 SHFT SOL 1 2 4 5 SHFT SOL SOL SUPPLY VOLT TEMP START SENSOR VOLT SENSOR GROUND N3 INPUT N2 INPUT TCM GROUND TCM POWER DATA D D OUT C OUT B OUT A OUT TRRS OUT POWER IN DATA C DATA B DATA A...

Page 28: ...SENSOR GROUND N3 INPUT N2 INPUT TCM GROUND TCM POWER CAN H CAN L RELAY IGNITION DATA LINE HOT AT ALL TIMES IGNITION Pink Brown Pink Black Pink Black Pink Black Black White White Red White Lt Green Whi...

Page 29: ...ts to a pre programmed fixed substitutionvalue L RR R RR 2500rpm A B in this column means with implausible signal input TCM defaults to a pre programmed fixed substitutionvalue A C in this column mean...

Page 30: ...Management Torque Implausible or Communication Error CAN Engine Management Torque Implausible CAN Throttle Valve Acutator Implausible CAN TRRS Mod N15 5 Implemented or Engine Management Fault CAN ME 1...

Page 31: ...ATIONS DLC No 1 DLC No 2 DLC No 3 DLC No 4 This DLC is located in the engine compartment and is a 16 pin diagnostic connector which will require a Code Reader and willproduce2digitcodes This DLC is lo...

Page 32: ...unction Transmission Fluid Temperature Sensor Circuit Transmission Fluid Temperature Sensor Low Transmission Fluid Temperature Sensor Intermittent N2 Input Speed Sensor Circuit No Signal Incorrect Gea...

Page 33: ...Recieved From ABS Module Implausible Data Recieved From Instrument Cluster Implausible Data Recieved From HVAC Control Module Implausible Data Recieved From Front Control Module Lost Engine Coolant M...

Page 34: ...uid s return path is between the statorshaftandturbine shaft The TCM controls the converter clutch apply with Electronic Modulated Converter Clutch EMCC software using theTCC PWM solenoid and theTCC v...

Page 35: ...M 215 5 4 MM 215 5 4 MM 215 5 4 MM 215 5 4 MM 215 5 4 MM 215 5 4 MM 215 5 4 MM 215 Material Steel Steel Steel Steel Steel Steel Steel Steel Plastic Plastic Plastic Plastic Function K1 Clutch Exhaust K...

Page 36: ...n Off Pressure To Cooler From TCC Control Valve Torque Converter In From TCC Control Valve Torque Converter Out To TCC Control Valve Pump Suction Pump Pressure B2 B3 B2 Counter Pressure K3 Case Passag...

Page 37: ...Pump Pressure TC Fluid In TC Fluid Out To Cooler TCC On Off Case Passage Identification Converter Housing Side Converter Housing Passage Identification CASE PASSAGE IDENTIFICATION K1 TC Fluid Out To...

Page 38: ...Vent TC Fluid In OIL PUMP COVER PASSAGE IDENTIFICATION Copyright 2009 ATSG Figure 38 Hold Freewheel F E R L H E E E W K 1 DRUM AND SUN GEAR SHOULD FREEWHEEL COUNTER CLOCKWISE AND LOCK CLOCKWISE 0 2 07...

Page 39: ...you must observe carefully in order to reduce the risk of injury to yourself or others This manual also contains NOTES that must be carefully followed in order to avoid improper service that may dama...

Page 40: ...sition to prepareforremovalof theoutputshaft nut 10 Removetheoutputshaft drive yokeretaining nut usinga30mm 12 point socket as shown inFigure43 11 Removetheoutput shaft driveyoke as shown inFigure43 1...

Page 41: ...facingupasshown in Figure 45 16 Removethesix oil pan bolts and the spacers as showninFigure45 17 Removetheoil pan removeand discard oil pan rubbergasket as shown in Figure 45 Continued on Page 42 Figu...

Page 42: ...D 18 Removetheoil filterby pulling straightup as showninFigure 46 and discard filterand the O ringseal 19 Removethecase to electricalconductor plate sealingsleeve as shown in Figure 47 Note Youmust re...

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