Transcription

"2011” SEMINAR INFORMATION8MERCEDES BENZ 722.9PRELIMINARY INFORMATIONMercedes Benz has produced a new 5th generationelectronically controlled gearbox with seven forwardand two reverse speeds.Vehicle Application/Transmission DesignationThe W7A 700 is the only model size 722.9 beingproduced at the time of this written material, a smallermodel the W7A 400 will be introduced at a later time.This transmission is referred to as:NAG 2 (Neues Automatische Getriebe 2)New Automatic Gearbox 2 or 7G- TronicVehicle Applications:Select non 4MATIC (2WD) MY 2004 vehiclesw/M113 engine.S340, S/CL/E/SL500Optional:SLK (R171-09/04)Standard Equipment:CLS 350 (late 2004)E350 (late 2004)M Class (W164-2005)R Class (W251-2005)G Class (X164-2006)End of production models that will unlikely receivethe 722.9 would be W163, R170 & V463.722.9 for W164/W251/X164 will be equipped withshift by wire (no shifter rod or cable). An electroniccontrol module on the left rear side of thetransmission just above the pan rail which operates ashift control valve and its position is monitored by aposition sensor.The 722.6 (NAG 1 or V) will continue productionuntil approximately MY 2012 and installed in:4 cyl modelsMaybachM275 vehiclessome select manufacturer’s contract vehiclesFluid TypeNewly developed suggested use “only” transmissionfluid, referred to as “ATF 3353 with higher frictionconsistency, thermal stability and temperature rating.Can also be used on previous model 722.3/.4/.5/.6transmissions. No scheduled maintenance required(fill for life) and available at Shell & Fuchs Europe oilsuppliers in 1 liter bottles under Mercedes Benz partnumber A001 989 45 03 10.Electronic Control ComponentsThe Transmission Control Module (Y3/8n4) which isCopyright 2011 ATSGflash capable, along with the following components:Eight Solenoids:Working Pressure Control Solenoid(Y3/8y1)K1Clutch Solenoid (Y3/8y2)K2 Clutch Solenoid (Y3/8y3)K3 Clutch Solenoid (Y3/8y4)B1Brake Clutch Solenoid (Y3/8y5)B2 Brake Clutch Solenoid (Y3/8y6)B3 Brake Clutch Solenoid (Y3/8y7)Torque Converter Lock Up Solenoid(Y3/8y8)Two Oil FloatsOil Control Float 1 (31)Oil Control Float 2 (32)Three Speed SensorsTurbine RPM Sensor (Y3/8n1)Internal RPM Sensor (Y3/8n2)Output RPM Sensor (Y3/8n3)Selection Range Sensor (Y3/8s1)are all integrated into the valve body assembly.Shift StrategyThe shift strategy improvements include:! Shorter computer reaction time by 0.1 second! Downshifts shortened by up to 0.2 seconds! Coasting downshifts shortened by 0.4/2.5 seconds! 37-47 MPH acceleration times shortened by 2328% (model dependant)! Fuel consumption reduced by up to 4%! Noise levels reduced, due to lower engine speed in5th, 6th & 7th gear at constant vehicle speed! Flexible adaptation to vehicle and engineVariable Shift ProgramingTwo basic shift programs can be varied by customer(same as 722.6) using the S/C button on theElectronic Shifter Module (ESM)“S”( Sport)1st gear startsNormal shift pointsReverse gear 1 (-3.416:1)“C” (Comfort)2nd gear startsEarlier up-shifts and later downshiftsReverse gear 2 (-2.231:1)Note: Transmission will start in first gear if any ofthe following conditions apply:1st gear is manually selected3/4 to full throttle acceleration from startCold engine temp (pre catalytic warm up)Automatic Transmission Service Group

"2011” SEMINAR INFORMATION9MERCEDES BENZ 722.9PRELIMINARY INFORMATIONShift Optimal Gear (SOG)Shift into Optimal Gear software as known in previousmodels .Up shifts and downshifts based on driving style andengine load (similar to 722.6)Shift interlock controlled by Electronic ShifterModule (ESM) same as previous modelsEmergency function/Limp-home mode:There are a variety of failsafe modes; if a solenoid isdefective the gear affected is blocked (examplesolenoid Y3/8y7-B3 clutch is defective: no 1st, 7th orReverse in “S” mode) If hydraulic fault prevents a gearfrom engaging then the previous gear will be applied.If the computer defaults while driving, all solenoidswill be turned off. Solenoids that are normally openwill allow full pressure to selected clutches and thetransmission will be in 6th gear. After shifting to “P”oil pressure from K2 solenoid is redirected to B2/BRsolenoid via emergency operation valves and thetransmission will now achieve 2nd in “D” andReverse.Gear RatioThe gear ratios are achieved with four multi-discbrakes and three multi-disc clutches, no free wheelsunits (sprags)There are three planetary gear sets:Two simpleOne RavigneauxTorque Converter (same used in some 722.6)Torque converter operates in open or slip mode in allseven forward gears.Lock up converter is never fully locked.Converter is open in 1st & 2nd gear if throttle andoutput shaft speed are in “Zone A”Converter is in slip-control in all 7 forward gear ifthrottle and output shaft speed are in “Zone B”. Oilfeed pressure to the converter is varied depending onthe amount of desired slip.Open: High flowSlip Control: Lower flowLock up clutch will turn off and transmission will shiftto a lower gear at oil temperatures of 140C or higher.Holds 4 liters of fluidIncorporates damper springs integral to lock up clutchto reduce vibration.Copyright 2011 ATSGVehicle TowingIf vehicle must be towed it should be transported byuse of a flat bed trailer type of tow truck.Alternate towing with vehicle drive axle lifted.If either fore mentioned options are not available a towbar (preferred) will suffice under the followingconditions/limitations:1. Turn key to position 22. Selector lever to”N” position3. Max. towing speed 31 mph4. Max. towing distance 31 milesNote: If towing distance or speed exceeds prementioned values damage may occur to transmission.Clutch Clearances no. of disc 722.9 722.93(mm) (mm)B1 Brake32.0-2.442.2-2.6 2.2-2.652.3-2.7B2 Brake (internal tooth) 41.7-2.1 1.7-2.151.8-2.2 1.8-2.2(external tooth) 51.7-2.1 1.7-2.161.8-2.2 1.8-2.2B3 Brake32.0-2.4 2.0-2.442.2-2.6 2.2-2.652.3-2.7 2.3-2.7Br BrakeN/A1.0-1.4 1.0-1.4K1 Clutch32.0-2.442.2-2.652.4-2.8 2.4-2.862.4-2.8K2 Clutch31.7-2.141.9-2.352.1-2.562.2-2.6 1.9-2.372.0-2.482.1-2.5K3 Clutch32.4-2.842.2-2.652.4-2.8All clutch clearances are measured between theFlange and retainer ring, while applying the amount ofhand pressure listed below.B1 N 600B2 N 1000 B3 N 600BR N/AK1 N 800K2 N1200K3 N 600Note: B2 Brake multi disc clutches use single sidedplates at this point in time other clutch members mayuse single sided plates at a future date.Automatic Transmission Service Group

"2011” SEMINAR INFORMATION12MERCEDES BENZ 722.9PRELIMINARY INFORMATIONB3 Feed PortK1 (Y3/8y2)B1 (Y3/8y5)N.C./N.V.Green TopN.O./N.A.Black TopB3 (Y3/8y7) K3 (Y3/8y4)N.C./N.V.Green TopN.O./N.A.Black TopY3/8n3Y3/8n4Y3/8n1Y3/8n2Y3/8s1TCC (Y3/8y8)PCS (Y3/8y1)K2 (Y3/8y3)B2/BR (Y3/8y6)N.C./N.V.Green TopN.O./N.A.Black TopN.O./N.A.Black TopN.C./N.V.Green TopY3/8n1 Input speed sensor (front) - Reads Input Shaft SpeedY3/8n2 Middle speed sensor (center) - Reads Ravigneaux Carrier/Rear Internal Ring Gear SpeedY3/8n3 Output speed sensor (rear) - Reads Output Shaft SpeedY3/8n4 Electrohydraulic Control Module (TCM) (w/internal transmission fluid temp sensor)Y3/8y1 Working Pressure - (Normally Open/Normally Applied (Solenoid off High Pressure)Y3/8y2 K1 Clutch - Normally Closed/Normally Vented (Solenoid off No Pressure)Y3/8y3 K2 Clutch - (Normally Open/Normally Applied (Solenoid off High Pressure)Y3/8y4 K3 Clutch - (Normally Open/Normally Applied (Solenoid off High Pressure)Y3/8y5 B1 Brake - (Normally Open/Normally Applied (Solenoid off High Pressure)Y3/8y6 B2/BR Brake - Normally Closed.Normally Vented (Solenoid off No Pressure)Y3/8y7 B3 Brake - Normally Closed.Normally Vented (Solenoid off No Pressure)Y3/8y8 Lock-Up - Normally Closed.Normally Vented (Solenoid off No Pressure)Y3/8s1 Range sensorNote: Normally Open/Normally Applied solenoids are used when Limp Mode strategy has been initiatedwhen all solenoids are turned offCopyright 2011 ATSGAutomatic Transmission Service Group

"2011” SEMINAR INFORMATION13MERCEDES BENZ 722.9HALL AFFECT SPEED SENSORSMagnet Rings are covered byNon Ferrous MetalMagnet Ring Integral to theRavigneaux Carrier whichspins around the outsideof the K2 Clutch DrumPark PawlGearMagnet Ring Integral to theK2 Clutch DrumInput (Turbine) ShaftThe back Ravigneaux Ring Gearis integral to the K2 Clutch DrumY3/8n1Y3/8n2Y3/8n3Front speed sensor (Y3/8n1): monitors Input (Turbine) Shaft and back Ravigneaux Ring Gear speed.Center speed sensor (Y3/8n2): monitors Ravigneaux carrier and rear Ring Gear speed.Rear speed sensor (Y3/8n3): monitors Output Shaft speed from exciter ring on the Park Pawl gearNote: Magnets are molded in a plastic ring and secured inside Non Ferrous flangesCopyright 2011 ATSGAutomatic Transmission Service Group

"2011” SEMINAR INFORMATION14MERCEDES BENZ 722.9RANGE SENSOR & ELECTRICAL CONNECTOR5 PIN CONNECTOR(2 round o-rings & 1 square o-ring)321FLUID LEVELFLOAT45ELECTRICALCONNECTOR1: CAN C High2: CAN C Low3: Diagnostic Line4: Circuit 87 (relay & fuse depending on model)5: Circuit 31Y3/8n4Y3/8s1FLUID LEVELFLOATRANGE SENSORThe Range sensor (Y3/8s1) is integral to the TCM conductor plate and is not replaced separately. A magnetlocated on the Manual Valve signals its position through sensor pick ups referred to as: Permanent MagneticLinear Contact-less Displacement Sensor (PLCD). If this is a failsafe item should it become faulty or thesignal is not learned.Fluid Level Floats (2):To prevent oil foaming from gears running in fluid. The front one was added due totransmission extended length (41mm) causing oil to slosh during hard forward stops.Copyright 2011 ATSGAutomatic Transmission Service Group

"2011" SEMINAR INFORMATION16MERCEDES BENZ 722.9SOLENOID APPLICATIONSOLENOID APPLICATION & SOLENOID FUNCTIONCLUTCH/BRAKESOLENOIDGear RatioB1B2/BR*B3K1K2K3Y3/8y5N.O. (M)Y3/8y6N.C. (M)Y3/8y7N.C. (M)Y3/8y2N.C. (M)Y3/8y3N.O. (M)Y3/8y4N.O. allyVentedNormallyAppliedNormallyAppliedCurrent Psi fromCurrent Psi fromCurrent Psi fromCurrent Psi fromCurrent Psi fromCurrent Psi fromto Solenoid Solenoid to Solenoid Solenoid to Solenoid Solenoid to Solenoid Solenoid to Solenoid Solenoid to Solenoid SolenoidHighLowVarying Varying Varying VaryingLowLowHighLowVarying VaryingLowLowHighLowVarying VaryingHighLowVarying Varying14.37722.859 Varying Varying Varying VaryingLowLow31.921HighLowVarying VaryingLowLowVarying Varying41.368HighLowVarying VaryingLowLowVarying Varying Varying Varying51.000HighLowLowLowLowLowVarying Varying Varying Varying Varying Varying60.820 Varying Varying LowLowLowLow70.728N (1)N (2)R (1) -3.416HighLowLowLowVarying Varying Varying VaryingHighLowLowLowVarying VaryingLowLowVarying Varying Varying VaryingHighLowLowLowVarying VaryingLowLowHighLowVarying VaryingLowLowLowLowHighLowVarying Varying(BR)(BR) Varying VaryingLowLowHighLowVarying VaryingLowLowHighLowVarying VaryingVarying VaryingHighLowLowLowVarying Varying(BR) (BR)R (2) -2.231 Varying Varying Varying Varying LowLowN.O. (M) Mercedes nomenclature for Normally Open. This refers to the Solenoid feed connection to Solenoidoutput pressure. To Simplify, Normally Open Solenoid feed is connected to Solenoid output when theSolenoid is OFF, ATSG refers to that as Normally Applied.N.C. (M) Mercedes nomenclature for Normally Closed. This refers to the Solenoid feed connection toSolenoid output pressure. To Simplify, Normally Closed Solenoid feed is blocked to Solenoid output when theSolenoid is OFF, ATSG refers to that as Normally Vented.*B2 & BR share the same solenoid the oil is directed to a different clutch members by the selector shift valveFailsafe while driving all solenoids will be turned off, transmission will shift to 6th gear.After engaging Park then Drive: only 2nd & Reverse gear are available.Copyright 2011 ATSGAutomatic Transmission Service Group

"2011” SEMINAR INFORMATION17MERCEDES BENZ 722.9CLUTCH POSITION & APPLICATIONB1B3K2BRK3B2K1NO FREEWHEEL (SPRAG)GearGear RatioW7A 0.728XXB1XB2B3XXK1-3.416R (2)-2.231K3XXXXXXXXXR (1)K2XN (1)(1) S ModeBRXXXX(2) C Mode (X) AppliedCopyright 2011 ATSGAutomatic Transmission Service Group

"2011” SEMINAR INFORMATION18MERCEDES BENZ 722.9SHIFT SEQUENCESB1B2B3K1K2K3XXXXXXXXX7th Gear6th GearX5th Gear4th GearXX3rd GearXX2nd Gear1st GearXXXXRelease B3XXX76Apply K15Release K24Apply B23Release K1Apply B3Apply B221The 722.9 transmission has Sequential shifting (clutch on clutch) in addition to providing a down shiftstrategy that allows the transmission to skip gears during down shifts as long as one clutch member isreleased as another is applied.Copyright 2011 ATSGAutomatic Transmission Service Group

"2011” SEMINAR INFORMATION19MERCEDES BENZ 722.9POWER FLOWB1B3K2BRK3B2K1GearRavigneauxCenter Planetary(Rear Internal Ring Gear)(Output Shaft)Rear PlanetaryFirst2.25:1 ReductionReductionReductionSecond1.50:1 .50:1 ReductionOverdrivenOverdrivenSeventh2.25:1 ReductionOverdrivenOverdriven* The Ravigneaux gear set drives the rear internal ring gear. For every 1 revolution of the ringgear both the rear and middle sun gears are forced to rotate 2.5 times (when the K3 clutch is applied).The rear carrier and middle internal ring gear are being driven at input speed via the K2 clutch.The difference between the speed of the middle sun gear and the middle internal ring gear causesthe middle carrier and output shaft to rotate at an overdrive speed of 0.820:1 in 6th and 0.728:1 in 7th.Automatic Transmission Service Group

"2011” SEMINAR INFORMATION20MERCEDES BENZ 722.9POWER FLOWPower Flow 1st GearB1B3BR8K21162B25K3912463K1151814117Input Torque101317Input ShaftOutput ShaftThe Ravigneaux Planet Small Ring Gear (5) is driven by the Input Shaft. The Long Planet Gears (15) drive theShort Planet Gears (16) to rotate inside the Large Ring Gear