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Topic: The Mercedes automatic transmissions (models 722.3, 722.4, 722.5, 722.6)-guidance on repair and Diagnostics.

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    The Mercedes automatic transmissions (models 722.3, 722.4, 722.5, 722.6)-guidance on repair and Diagnostics.

    Technical manual and automatic transmission diagnosis
    The Guide gives step-by-step operations for removing and installing, Assembly and disassembly of automatic transmissions cars Mercedes. Describes in detail the rabotasistemy control. The possible faults and remedies, describes the design features of the gearboxes and Mercedes 722.5 722.4. The annexes contain all necessary for operation, maintenance and repair of Mercedes Benz details. Mercedes models 722.3, 722.4, 722.5, 722.6. hydraulic


    Chapter i. Mercedes 722.3, 722.4 7
    1. General device 8
    2. control features an automatic transmission 11
    Getting traffic 11
    Stop 11
    Towing Mersedes 11
    Accidental starting of the engine with the tugboat 11
    3 Hydraulic control system 11
    The main and auxiliary pumps 11
    Valve box 12
    Formation of working pressure 12
    The influence of vehicle speed 13
    The influence of power, developed engine 14
    Formation pressure modulator 15
    Pressure lubrication system 16
    Forming pressure control valve-throttle 16
    Formation pressure speed control 19
    Increased pressure speed Governor 20
    Pressure prop 20
    21 gear shift control system
    Reverse switch in movement (work of Jet valve) 25
    Slide range modes of automatic transmission 26
    System battery 27
    Control system forced lowering transfer 29
    Work programme switch 30
    4 gearbox lubrication system 31
    Periods of service 31
    Oil level 31
    Oil capacity 31
    Drain and change oil 31
    5 adjust the 31
    31 range switching system
    Cable-throttle valve control 32
    Range selection lever position sensor in position "N 33
    Check the pressure in the control system of the automatic transmission 33
    Pressure modulator 34
    Working pressure of 35
    Pressure speed Governor 35
    Check the vacuum circuit 36
    6 road test 37
    Service vehicle 40
    7 Modification of transmission and control system of 40
    Modulator 40
    The modification of the valve-throttle Mercedes 722.3 1986 and subsequent years of issue 41
    Modification of piston and piston rod B1 42 band brake
    Later modifications of valve box 43
    Identification of the distribution of plate valve box 44
    Band brake piston modification B2 44
    8. Alerts and tips 45
    Mount the modulator Mercedec 45
    Location of nozzles and valves 46
    Primary pump automatic transmission 722.4 47
    Replace o-ring (RC-5601) in the aluminum pole sleeves K1 47
    Replacing the o-ring in the aluminium coupling support K2 48
    Lubrication system modification back 48
    9. Troubleshooting Troubleshooting 49
    Faults: transmission slips at all ranges 49
    Slip on the second pass, or switches with 1 second on 3-th transfer 49
    Slipping when starting with the 1-St 2-nd or transfer or even ~
    You can't move forward but reverse movement occurs normally 4S
    Slide switch 2-3 or glide
    at the beginning of the switch and enable transfer at the end of a dramatic 49
    Slide switch 3-4 43
    In the gearbox there is a tight connection between the lead and driven shafts or it is broken after a short period of 50
    Some time after the engine starts, the vehicle remains stationary in all positions of the range selection lever (especially after a long parking) 50
    In the gearbox there is a tight connection between the lead and driven shafts in reverse gear 50
    A sharp Jolt when installing the range selection lever at position "D" or "R 50
    When you switch to transfer the vehicle sharply twitches 50
    The sharp rise in transfer 4-3 51
    The dramatic switch with partial load engine 51
    No forced downshift 51
    No brakes when switching (4-3 and 3-2) 51
    Unwanted downgrading the transfer with a slight push on the throttle pedal 51
    No more switching 51
    Switch to a higher gear is only in the upper RPM range of the engine 52
    Switch to a higher gear is only in the lower engine speed range 52
    The motor does not start when you install the range selection lever to position "p" or "N 52
    Reduce oil level (without external signs of leaks) and the emergence of more dark exhaust smoke 52
    Oil leak in the transformer or main pump (the appearance of oil on the vent grille) 52
    A howling sound, increasing with increasing engine speed 52
    A rattling sound when engine speed 1500 rpm at all ranges except the reversing range (R) 5z
    A small Squeak in the range selection lever in the "p" and "N 53
    Rattling noise when driving on reverse transfer 53
    Low acceleration when driving from 53
    The parking mode is 53
    Range selection lever is not raised in the "R" and "p 53
    The transmission oil engine coolant was 53
    Transmission was running in first gear and reverse gear 54
    Noise in third gear 54
    Howling noise only when switching and traffic with ultimate load 54
    Later the gear shift forward on all bands (Mercedes 722.3/722.4 1980 -1991 year of production) 54
    There are oil leaks at the front of the transmission seal replacement and overhaul 1
    (Mercedes 722.3 early models 1980-84, (6 bolt Pan)) 54
    Some gearboxes series 190 after overhaul there may be drastic modes enable reverse gears. All transmissions are normally forward and pressure modulator is within an acceptable range (Mercedes 722.4) 55
    Hard switching to the ranges "D" and "R" and knock the universal drive shaft into the range of the lever "D" or "R 55
    Sharp turn on only the rear transfer (Mercedes 722.4) 56
    Overheating transmission oil; It is very dark or black, but not smells (Mercedes 722.4 production from July 1986 to February 1987) 57
    Random 4-3 and 3-2 gear 57
    After the capital repairs of Mercedes, equipped with an automatic transmission or a 722.4 722.3 slipping in reverse gear or it will not turn on, 57
    Slips at the initial stage and subsequent transfer shall be included in the rigid rear; automatic transmission becomes neutral when you release the pedal, the throttle and goes to work on her back you move; will not turn on, or the very hard-going pereklûčenie3-4 (Mercedes 722.4) 59
    10. adjusting the friction controls automatic transmission 60
    Adjusting the band brake B1 60
    Adjusting the band brake B2 60
    The length of the piston stroke in the locking sleeves 61
    The length of the piston stroke in the disk brake VZ 61
    11. repair of the valve chest 62 MB
    Removing the valve box Mercedes Benz 62
    Dismantling and assembling the valve chest 64
    12. Speed control knob and the rear (auxiliary): pump removal and installation 67
    13. removing and installing automatic transmission 74
    14. Disassemble automatic transmission 79
    15. building automatic transmission 87
    16. Assembly and disassembly of the front of the automatic gear box 104
    17. Assembly and disassembly of the planetary mechanisms 106
    18. disassembly, Assembly and adjustment of clutch K1 110
    19. disassembly, Assembly and adjustment of clutch K2 113
    Chapter II. Mercedes 722.5 117
    1. control features an automatic transmission 722.5 117
    2. adjustment of 121
    Removal, installation and adjustment of a rope of vacuum pressure control element for vehicles with program selection switch system operation control 122
    3. check the operation of the automatic transmission in 124
    Check the movement of 124
    Speed value, the corresponding switching points 125
    4. repair of valve box (supplement to 722.3/722.4) 126
    5. dismantling, assembling and adjusting the brakes rear planetary series 128 BS
    6. disassembly, Assembly and adjustment of the locking sleeve KS 130
    Installing couplings 130
    Operations that must be performed after disassembly of couplings 135
    Assembly 135
    Disassembly-Assembly clutch free running 137
    7. range selection lever lock System on models 1990 year issue 138
    Switching delay 2-3 when the engine coolant temperature is below 40° c 139
    9. protection of the automatic gearbox from overload 140
    Backup system 140
    10. Switch on fifth gear 140
    Chapter III. Mercedes 722.6 141
    1. General information of 141
    2. identification of the gear box 141
    3. the device of gear box 141
    Carter Mersedès 141
    Transmission Mèrsedes 142
    Electro-hydraulic control unit 142
    143 gearbox control
    Device and system for selecting a range of gear 144
    The locking bolt output shaft GEARBOX 146
    Ignition key lock 146
    Maintenance instructions GEARBOX 147
    Torque converter 148
    Planetary grinder 148
    The mechanism of blocking the output shaft AUTOMATIC TRANSMISSION 150
    The mechanism of regulation of the oil level in the GEARBOX 150
    Crankcase ventilation system AUTOMATIC 151
    4. automatic control system of 151
    Electronic automatic control unit (EGS) 151
    Program switches 151
    Interaction with 152
    Control lock the torque converter clutch 152
    Adaptation of 152
    The input and output signals from the AUTOMATIC TRANSMISSION control unit 152
    lock the torque converter clutch 154 Board
    Electro-hydraulic control unit 154
    Solenoids 155
    Output shaft speed sensor AUTOMATIC 155
    The safety sensor (ASK) 155
    Oil temperature sensor 155
    Oil pump 157
    Working pressure (p-a) 157
    Pressure grease (p-Sm) 157
    Pressure modulation (Mod p) 157
    Pressure switch (p-S) 158
    Pressure regulating solenoids (p-r) 158
    Pressure switch solenoids (p-SV) 158
    Locking torque converter clutch control valve 158
    Group gear 158
    Group switch K1/B1 159
    Group switch K2/CZ 159
    Group switch SHORT CIRCUIT/B2 159
    Pressure valve overlap (RS-U) 158
    Valve activation gear 159
    Pressure equalization valve 160
    Valve switching 160
    Switch 1-2 160
    Processes that occur when a range selection lever from the "N" position to the "D" (the inclusion of the first transfer) 161
    5. diagnosis of gear box Mèrsedes 162
    Trouble codes transmission car with 722.6 162
    The diagnostic connector (DLC) 166
    Transmission identification 168
    Changing the design of the locking clamp adaptor output shaft GEARBOX (PLIL) 175
    6. disassembly of the drive train 177
    Disc brake assembly and disassembly of the B1 178
    Disc brake assembly and disassembly of the B2 180
    Pressure inlet openings 181
    Disc brake assembly and disassembly of the EOI 182
    Led front planetary number of 184
    Locking sleeve K1 186
    Driven shaft 186
    Adjustment of axial runout of shaft driven 190
    7. electro-hydraulic control unit 191
    Disassembly and Assembly of electric hydraulic control unit (722.6 transmission type 129, 140, 163, 170, 202, 208, 210, 211, 215, 220, 230, 240; 722.6 transmission type 461.302/332/342/345, 463.206/209/232/233/240/241/243/244/245/246/247/248/249/250/254/308/309/322323/330/331/332/333) 197
    Disassembly and Assembly of electric hydraulic control unit (transmission type 722.610 463.209/323/244/245/250; transmission type 722.6611 463.308/330/331; transmission type 722.630 463.206/240/241/243/246/247/248/249/254; transmission type 722.637 461.302/332/342/345, 463.322/323; transmission type 722.638 463.309/332/333) 201
    Application 1. General scheme of the hydraulic control system of gear box 722.6 20 g
    Annex 2. Plan of the angular velocity and the kinematic scheme of automatic gearboxes 722.3, 722.4, 722.5 (without accelerating the planetary range) 204
    Annex 3. Calculation of the loading of the gearbox 204
    Annex 4. Color illustrations

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    Last edited by AutoFan; 24.02.2015 in 07:58.
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