WEISTEC 722.9 Transmission Service Data

WEISTEC 722.9 Transmission Service DataTRANSMISSION12722.950 /960 /961 /962 /963 /964 /965 /966Overflow pipeAdapter3Oil drain screwaConstant oil flow for excessively largeoil filling capacity and at start of oiladjustmentCorrect oil filling capacity afterdraining off excess quantitybThe transmission must be filled withtransmission oil before starting the engine1Raise vehicle23Check the transmission oil pan for damageand leaktightnessRemove rear engine crossmember45Lower transmission/transfer case at rearPrefill transfer case with transmission oil6Install rear engine crossmemberThe vehicle must be situated on thelifting platform so that it is level in both thelongitudinal and transverse axes.Model 216, 221Model 204Remove the oil filler screw from thetransfer case, pour the prefill quantity (700ml) into the transfer case and screw in anew oil filler screw.Model 216, 221Model 204

7Remove oil drain screw (3) on transmission,The adapter (2) and oil dispenser can bemount adapter (2) and connect oil dispenser obtained from two manufacturers:8Pump 6 liters of transmission oil intotransmissionIn order to avoid damage to thetransmission, always consult theSpecifications for Operating Fluids.On transmissions which have beenrepaired the quantity of transmission oildrained 0.5 liters should be poured in.910Start engineCall up the transmission fluid temperatureusing STAR DIAGNOSISConnect STAR DIAGNOSIS11.1Bring transmission oil temperature to90 C/194 FVehicles with additional transmission oilcoolerOnly with previous removal/replacementof additional transmission oil cooler.Thermostat opens at 90 C/194 F.11.212.1Bring transmission oil temperature to45 C/113 FSwitch off engine and allow transmission oilto cool down12.2Turn off engine13Call up the transmission fluid temperatureusing STAR DIAGNOSIS14Start engine and allow to run in selectorlever position "P"Pump transmission oil using oil dispenserinto transmission15Engine speed 2500 rpm, selector lever inposition "P".Vehicles without additional transmission oilcoolerVehicles with additional transmission oilcoolerOnly with previous removal/replacementof additional transmission oil cooler.Vehicles without additional transmission oilcoolerTransmission oil temperature45 C/113 F .The transmission oil temperature must notexceed the specified value as the overflowpipe (1) in the transmission oil pan isdesigned for the transmission oiltemperature.After replacing the transmission andtorque converter :Refill 4 liters of transmission oil.If the torque converter has not beenemptied:Refill 2 liters of transmission oil.1617181920Correct transmission fluid levelShift through "P-R-N-D" several times withthe vehicle stationary and the engine idlingAllow engine to idle in selector lever position"P"Call up the transmission fluid temperatureTransmission oil temperatureusing STAR DIAGNOSIS45 C/113 F .The transmission oil temperature must notexceed the specified value as the overflowpipe (1) in the transmission oil pan isdesigned for the transmission oiltemperature.Remove the adapter (2)Drain off constant oil flow (arrow a) atTransmission oil temperaturespecified transmission oil temperature, until 45 C/113 F .only drops come out (refer to correct oilThe engine must run at idle speed and thefilling capacity (arrow b))transmission oil temperature must not beabove the specified transmission oiltemperature, too much transmission oil isdrained at a higher transmission oiltemperature.If the oil flow is not constant afteropening the drain screw, the transmission oillevel has to be corrected (as of operationstep 15) and then adjust it again.2122Replace sealing ring and screw in oil drainscrew (3)Turn off engine

Oil pan, automatic transmissionNumberDesignationOil drain screw to oil panTransmission722.9Nm22Transfer case completeNumberDesignationTransmission722.96Oil filler screw to intermediate housingNm20Automatic l chargeLiters99,7during oil changeLiters--Specifications for OperatingFluidsSheet--Sheet

Drain gear oil from torque converterTorque converterOil drain bolt to torqueconverter1Take out cover (1) from bell housing.2Turn the engine in the direction ofengine rotation until the drain screw (2a)on the torque converter (2) isaccessible.M8Nm10M10Nm153Remove drain screw (2a) from torque converter (2) and allowATF to drain.4Replace sealing ring of drain screw (2a) and screw drain screw(2a) into the torque converter (2)5Insert cover (1) in bell housing.

Remove/install automatic transmission oil panTRANSMISSION722.9Illustration shows transmission oil pan (3) without sloped surface and with black overflow tube (31)133aTransmission housingTransmission oil panSpragDanger !13b3132BoltsOverflow pipeMagnettoppling off of the lifting platform.Check transmission oil pan (3)Oil pan and overflow tube modifiedOil pan and overflow tube modified3334SealOil filterposition the four support plates at the vehiclelift support points specified by vehiclemanufacturer.Only category P with transmission 722.9 as ofproduction date 21.6.2010 with engine 113,156, 157, 271, 272, 273, 275, 276, 278, 642,651Only category P with transmission 722.901The transmission oil pan (3) and overflowpipe (31) have been redesigned to optimizethe oil supply to the A/T. The previoustransmission oil pan (3) without chamfers andwith a black overflow pipe (31) after removal isto be replaced by a transmission oil pan (3)with chamfers and with a white overflow pipe(31).Clean2Clean transmission oil pan (3) andsurrounding area thoroughlyCleanliness is essential when working on thetransmission.Otherwise, even the smallest foreign particle inthe hydraulic components of the transmissioncan lead to malfunctions or a total failure of thetransmissionFor cleaning, use lint-free cleaning cloth.Chamois leathers are the most suitable.

3Drain the transmission oil and collect fordetermining the quantity of transmissionRemove drain screw and pry overflow pipe(31) offfrom the base (arrow) with drift.The remaining transmission oil drains outimmediately after prying off.Installation: Replace seal.Oil drain screw to oil panDriftDetach transmission oil pan (3) fromtransmission housing (1)4Installation:The sprags (3a) are only permitted fortransmission 722.9 and they may not be mixedup with sprags for other transmissions.Contact corrosion can occur otherwiseInstallation: Replace bolts (3b).Screw/bolt, oil pan to transmissionhousing5Remove overflow pipe (31) from thetransmission oil pan (3)The distance from the upper edge of theoverflow pipe (31) to the base of thetransmission oil pan (3) determines the fillingcapacity of the transmission.Installation: Replace overflow pipe (31)and press firmly onto the base (arrow).6Remove seal (33)Installation:Do not coat any sealant or sealing componenton transmission oil pan (3) and transmissionhousing (1).Leaks can occur otherwise.Installation: Always replace seal (33).Clean7Remove and clean the magnet (32) from theInstallation: Check the magnet (32) fortransmission oil pan (3)damage and replace if necessaryClean the transmission oil pan (3)Installation:Sealing surfaces must be absolutely free of oiland grease.Leaks can occur otherwise.8Installation: Have the cleaning sprayscompletely extracted.910Check oil filter (34) and replace if necessaryInstall in the reverse order11Fill transmission with transmission fluidTRANSMISSION 722.9 (except 722.96)TRANSMISSION 722.96It is very essential to observe the workprocedure and Specifications for OperatingFluids.Otherwise the transmission may be damaged.Oil pan, automatic transmissionNumberDesignationOil drain screw to oil panNmTRANSMISSION722.922Nm TRANSMISSION722.94180Oil pan, automatic transmissionNumberDesignationScrew/bolt, oil pan to transmission housingStage 1Stage 2

Remove/install control solenoid valves of electric controller unitTransmission722.9Shown here transmission 722.9 in 5Y3/8y6Y3/8y7Y3/8y8Y3/8y9ABoltsLeaf springsValve body assemblySealSealFully integrated transmissioncontrol control unitControl solenoid valve workingpressure (black cap)Clutch control solenoid valve K1(blue cap)Clutch control solenoid valve K2(black cap)Clutch control solenoid valve K3(black cap)Control solenoid valve disk brakecontrol B1 (black cap)Control solenoid valve disk brakecontrol B2 (blue cap)Control solenoid valve disk brakecontrol B3 (blue cap)Control solenoid valve torqueconverter lockup clutch (bluecap)Control solenoid valve wet clutch(blue cap)If the control solenoid valve looks likethis after cleaning, it needs to bereplacedBClean control solenoid valve; if it lookslike this after cleaning, it can beinstalled againCControl solenoid valve OK, can beinstalled againElectrohydraulic controller unitDesignationBolt, solenoid valve to shift plateTransmission 722.9Nm8

Service Information: Additional adaptation counter indicatorTransmission722.9Since the end of 2012, a modified transmission adaptation hasbeen performed. This change relates to the adaptation counter for gearadaptation. The values are now indicated not only acoustically but alsoin the various temperatures "cold", "warm" and "hot" using a frequencycounter. This is intended to make checking of the performedadaptations verifiable and clearer.Only the model series as of model 204 which are compatible withXentry Diagnostics can be processed.Additional "adaptation counter" display(shown in German)The highlighted area on the right of the pictureis the additional display for the counters abovethe individual temperature interpolation points.Additional "adaptation counter" display(shown in English)The highlighted area on the right of the pictureis the additional display for the counters abovethe individual temperature interpolation points.

Weistec- 722.9 Air Check Pressure Testing LocationsBRB2K3B3B1K2

Oil pan and overflow tube modified Only category P with transmission 722.901 The transmission oil pan (3) and overflow pipe (31) have been redesigned to optimize the oil supply to the A/T. The previous transmission oil pan (3) without chamfers and with a black overflow pipe (31) after removal is to be replaced by a transmission oil pan (3)