10 GEARSAugust2009

Mercedes 722.9 Preliminary Information; Part 3

T
his will be the last of the
articles providing preliminary
information on the 722.9
I promise. This article provides the
powerflow charts (figures 1-9) which
include a detailed explanation for the
components in use during each gear,
along with both reverse gear ratios.
Reverse has two ratios depending
on which shift mode youve select-
ed: comfort or sport. And the clutches
applied during each gear are highlight-
ed for quick identification. The final
drive ratio is noted at the end of each
component application.
Youll have to acquire the proper
software or scan tool to be able to
diagnose and fix one of these vehicles
properly the first time out.
About Gear Noises
In 3rd gear the components of the
Ravigneaux gearset are locked together.
If a gear noise goes away when the
transmission shifts into 3rd gear, look
for a problem in the front gearset.
In 4th gear the components of
the Ravigneaux and rear gearsets are
locked together. If a gear noise only
goes away in 4th gear, look for a prob-
lem in the rear gearset.
In 5th gear, all gearsets are locked
as one. If a gear noise disappears in 5th
gear, check the center gearset.
Power Flow; 1
st
Gear
The input shaft drives the
Ravigneaux planet small ring gear (5).
The long planet gears (PL2l) drive the
short planet gears (PL2k), and cause
them to rotate inside the large ring
gear (8), which is being held by the B3
brake. This increases the torque and
reduces the RPM to the dual planet
carrier (6).
The single rear planet ring gear
(9) rotates at the same speed, because
its connected mechanically to the dual
planet carrier. The planet gears (PL6)
rotate around the sun gear (11), which
is held by the K3 clutch; this in turn
rotates the planet carrier (10).
The single front planet ring gear
Mercedes 722.9
Preliminary Information;
Part 3
by Mike Souza
www.atra.com
SPEAKER
2 Turbine wheel A Input
3 Stator B Output
4 Impeller BR Multiple-disk brake BR
5 Small ring gear B1 Multiple-disk brake B1
6 Dual planet carrier B2 Multiple-disk brake B2
7 Sun gear B3 Multiple-disk brake B3
8 Large ring gear K1 Multiple-disk clutch K1
9 Ring gear K2 Multiple-disk clutch K2
10 Planet carrier K3 Multiple-disk clutch K3
11 Sun gear PL2k Short planet gears
12 Ring gear PL2l Long planet gears
Figure 1
4.38:1
Allison modulator adjustable white
Allison modulator adjustable white
Mazda GF4A-EL/4EAT-GF 1-2 Shift
Mitsubishi 3 ohm PWM lock-up 1987-93
Toyota A245/246 Lock-up Solenoid
GM 4L60E Internal Wire Harness w/ LU Solenoid
Chrysler 42, 44RE Gov. Pres. Sensor 3-pin 1993-96
Toyota U340E, SLT, EPC solenoid VW JF506E09A Low Timing / Low Clutch solenoid 1999-on
Mitsubishi On/off Shift B (all models)
GM 4L80E Internal Harness 2004-on OE
GM 4T80E Output Speed Sensor 1993-on (No Harness) OE
Toyota A541E Lock-up Solenoid 1994-up
Toyota A240/340 On/off Shift (2 per) solenoid
Mazda GF4A-EL/4EAT-GF Lock-up, EPC, PWM
Chrysler A500/518 Governor Pressure Sensor 93-99
Toyota A240 On/off Overdrive
GM 4L60E On/off Shift solenoid A & B
Ford C6 modulator adjustable purple
GM 4L60E Pressure Switch Manifold
Mazda GF4A-EL/4EAT-GF 3-4 Shift
Chrysler A500/518 Governor Pressure Solenoid
Chrysler A500/518 Dual Solenoid and harness 1993-99
Chrysler A604/606 Speed Sensor Re-
Mazda JF506E Neutral Shift Control solenoid
GM 4T65E Universal Internal Wire Harness 1997-up
Toyota U150, 151 SS3, SR 2002-on Shift #3 Position 2
Ford 5R55E EPC w/ Inductive Signal 1997-on OE
Mitsubishi Solenoid Master Kit (KM) 12 ohm Lock-up 1993-on
VW/Audi Universal Internal Harness 096(01M)/097(01N)
Chrysler A604, A606 Output Sensor
Toyota A245, 246E, 247E Lin
GM 4L60E Internal Wire Harness w/ Anti-bleed LU Sol. 1993-2002
GM 5L40E Shift 1-2, 2-3 & 4-5 solenoid 1999-on
OE
Allison LCT Internal Harness
Ford AXOD/AXODE On/off Lock-up solenoid
Ford 5R55E Input Case Sensor 1997-on
Mazda G4A-EL Solenoid kit w/ Harness
GM 4L65/70/75E Internal Harness w/ LU Sol. (Internal Sensor Design) 2006-08
GM 4T60E Internal Wire Harness 1994-on
Mitsubishi On/off Shift A (all models)
Chrysler A500/A518 External Repair Harness 1993-on
Volvo specinc A341E / 30-43LE LU Solenoid On/off
GM 350/400 modulator adjustable dual red
Ford 4R70W Internal Hard Wire Track 1998-up
Toyota A541E On/off Shift 1994-up GM 4L60E Anti-bleed Lock-up 1993-on with Quick Link Connectors
VW JF506E/09A Shift A 1999-on
Toyota U140E/F, U240E/F SL1, Shift 1
Ford RWD Differntial Mounted Speed Sensor 1990-
Toyota A140 On/off Shift 1
Ford AXODE MCCC 14.5 ohm 1997-on OE solenoid
Toyota A540 On/off Shift 1988-93
Mitsubishi 3 ohm EPC, PWM 1987-97
Ford 4R/5R Shift Solenoid 1995-on OE
Ford C6 modulator adjustable green
GM 4T80E Pressure Switch Manifold
GM 4L80E Pressure Switch Manifold
Chrysler A500 Overdrive & TCC Dual solenoid
GM 2-pin VSS External Repair Harness
GM Various FWD on/off Lock-up with Quick Link Connectors
Chrysler A500/518 SE Dual Solenoid and harness 2000-on
GM 4T60E Internal Wire Harness 1991-93 TCC PWM
Chrysler A404 TCC solenoid
Ford 5R110W Internal Wire Harness
Ford 4R100 Solenoid Block (PWM) 98-on OE
GM 4T60E Universal External Repair Harness 1991-on
Ford/Mazda 4F27E On/off Shift Solenoid 2000-on OE
GM 4T40E & 4T65E Shift solenoid A & B
Mazda GF4A-EL/4EAT-GF Lock-up Control
Ford 5R55E Input Center/Turbine Sensor 1995-96
Mitsubishi Solenoid Master Kit (KM) 3 ohm Lock-up 1987-93
Toyota U340E, U341E/F SL L/U solenoid
Ford E4OD solenoid External Repair Harness
Toyota A245E, A246E, A247E SLT EPC Solenoid
Ford AX4N EPC 95-on solenoid OE
VW JF506E09A Reduction Timing solenoid 1999-on
Jatco/Mazda modulator adjustable none
Mazda/VW JF506E Shift B 1999-on
Ford 5R110W TCC, Intermediate, Overdrive & Low Reverse (4 per) OE
GM 4T40E VSS 1995-on OE
GM TH400 VSS 1985-on OE
Toyota U340E, U341E/F
VW JF506E/09A 2-4 Brake Timing 1999-on
Toyota A140/240/340 2 pc. Shift Solenoid Kit
Toyota A140 On/off Shift 2 - OE Design
Toyota A240E Lock-up 1987-99
Volvo w/ GM 4T65E Input VSS 1999-on OE
GM 4L30E PWM Band Control Solenoid 90-99 OE on L/U
Mazda GF4A-EL/4EAT-GF 3-2 Downshift
Ford E4OD/4R100 Solenoid Block (Non-PWM) 95-on OE
Toyota A245/246 Lock-up Solenoid - OE Design
GM 4T40E Pressure Switch Manifold
Chrysler A604 solenoid External Harness Repair Kit
GM 350/400 modulator adjustable red
Ford 5R110W EPC / Line Pressure OE
Chrysler A604, A606 Input Sensor
Mazda F4A-EL/ 4EAT-F (F4E-III) EPC
Chrysler A500/518 Governor Pres. Sensor 2000-on
GM 4L80E PWM TCC solenoid
Toyota A341E, A341F, A343E, A343F SL Lock up
Ford AXODE On/off shift
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Chrysler 42RLE OSS, 2003-on
VW 095/096/097 Shift Solenoid OE
GM 4L80E Input & Output Speed Sensor
12 GEARSAugust2009
Mercedes 722.9 Preliminary Information; Part 3
(12) is connected mechanically to the
planet carrier (10), so it rotates at
the same speed. Planetary gears (PL9)
rotate around the sun gear (14), which
is held by the B2 brake, and transfers
the increased torque and reduced rota-
tional speed to the output shaft through
the planet carrier (13).
The output shaft rotates with
reduced input speed in the direction of
engine rotation at a ratio of 4.38:1.
Power Flow; 2
nd
Gear
The input shaft drives the
Ravigneaux planet small ring gear (5).
The long planet gears (PL2l) rotate
around the sun gear (7), which is held
by the B1 brake. This increases the
torque and reduces RPM, which is
transmitted to the dual planet carrier
(6).
The single rear planet ring gear (9)
is connected mechanically to the dual
planet carrier, so they rotate at the same
speed.
The planet gears (PL6) rotate
around the sun gear (11), which is held
by the K3 clutch. This rotates the planet
carrier (10).
The single front planet ring gear
(12) is connected mechanically to the
planet carrier (10), so they rotate at the
same speed.
The planetary gears (PL9) rotate
around the sun gear (14), which is
held by the B2 brake, and transfers the
increased torque and reduced rotational
speed to the output shaft through planet
carrier (13).
The output shaft rotates with
reduced input speed in the direction of
engine rotation at a ratio of 2.86:1.
Power Flow; 3rd Gear
With the K1 clutch engaged, the
Ravigneaux planetary gearset compo-
nents (5, 6, 7, 8, PL2l and PL2k) are
locked together and send input torque
and speed unchanged to the ring gear
(9).
The single rear planet ring gear (9)
drives the planet gear (PL6) to rotate
around the sun gear (11), which is held
by the K3 clutch; this rotates the planet
carrier (10). The single front planet ring
gear (12) is connected mechanically to
the planet carrier (10) so they rotate at
the same speed.
Planetary gears (PL9) rotate around
the sun gear (14), which is held by the
B2 brake, and transfers the increased
torque and reduced rotational speed to
the output shaft through planet carrier
(13).
The output shaft rotates with
reduced input speed in the direction of
engine rotation at a ratio of 1.92:1.
Note: In 3rd gear the elements of
Ravigneaux gearset are locked together.
If a gear noise goes away in 3rd gear,
look for a problem in the front gearset.
Power Flow; 4
th
Gear
With the K1 clutch engaged, the
Ravigneaux planetary gearset compo-
nents (5, 6, 7, 8, PL2l and PL2k) are
locked together, and send input torque
and input speed unchanged to the ring
gear (9).
With the K2 clutch engaged, the
single rear planet ring gear (9) and
single front planet ring gear (12) rotate
at the same speed. The single rear
planetary system is locked, so it isnt
involved in creating the gear ratio.
The engaged K2 clutch drives the
single front planet ring gear (12) at
input speed. The planetary gears (PL9)
rotate around the sun gear (14), which
is held by the B2 brake and transfers the
increased torque and reduced rotational
speed to the output shaft through planet
carrier (13).
The output shaft rotates with
2 Turbine wheel A Input
3 Stator B Output
4 Impeller BR Multiple-disk brake BR
5 Small ring gear B1 Multiple-disk brake B1
6 Dual planet carrier B2 Multiple-disk brake B2
7 Sun gear B3 Multiple-disk brake B3
8 Large ring gear K1 Multiple-disk clutch K1
9 Ring gear K2 Multiple-disk clutch K2
10 Planet carrier K3 Multiple-disk clutch K3
11 Sun gear PL2k Short planet gears
12 Ring gear PL2l Long planet gears
13 Planet carrier PL6 Planet gears
Figure 2
2.86:1
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D-17246-9_R03.indd 1 6/29/09 4:12:14 PM
14 GEARSAugust2009
Mercedes 722.9 Preliminary Information; Part 3
2 Turbine wheel A Input
3 Stator B Output
4 Impeller BR Multiple-disk brake BR
5 Small ring gear B1 Multiple-disk brake B1
6 Dual planet carrier B2 Multiple-disk brake B2
7 Sun gear B3 Multiple-disk brake B3
8 Large ring gear K1 Multiple-disk clutch K1
9 Ring gear K2 Multiple-disk clutch K2
10 Planet carrier K3 Multiple-disk clutch K3
11 Sun gear PL2k Short planet gears
12 Ring gear PL2l Long planet gears
13 Planet carrier PL6 Planet gears
14 Sun gear Pl9 Planet gears
16 Torque converter lockup clutch
Figure 3
Figure 4
1.92:1
1.37:1
GEARS August 2009 15
Figure 5
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16 GEARSAugust2009
Mercedes 722.9 Preliminary Information; Part 3
reduced input speed in the direction of
engine rotation at a ratio of 1.37:1.
Note: In 4th gear the components
of the Ravigneaux and rear gearsets
are locked together. If a gear noise only
goes away in 4th gear, look for a prob-
lem in the rear gearset.
Power Flow; 5
th
Gear
With the K1, K2 and K3 clutches
engaged, the power flow runs from the
input shaft via the locked Ravigneaux
planetary gearset components (5, 6, 7,
8, PL2l and PL2k) and the locked front
single planetary gearset (12, 13, 14 and
PL9) to the output shaft.
The output shaft rotates at the same
speed as the input shaft in the direction
of engine rotation at a ratio of 1:1.
Note: In 5th gear, all gearsets are
locked as one. If a gear noise is being
diagnosed and it only goes away when
in 5th gear, check the center gearset.
Power Flow; 6
th
Gear
The input shaft drives the
Ravigneaux planet small ring gear (5).
The long planet gears (PL2l) rotate
around the sun gear (7), which is
held by the B1 brake. This transmits
increased torque and reduced rpm to the
dual planet carrier (6).
The single rear planet ring gear (9)
rotates at the same speed as the dual
planet carrier, because theyre con-
nected mechanically. The planet gears
(PL6) rotate the sun gear (11), which
rotates the sun gear (14) through the
K3 clutch.
Input torque and input speed are
transmitted to the single front planet
ring gear (12) through the K2 clutch.
The speed difference between the sun
gear (14) and the ring gear (12) sends
increased speed and reduced torque to
the output shaft through planet carrier
(13).
The output shaft rotates with
reduced input speed in the direction of
engine rotation at a ratio of 0.82:1.
Power Flow; 7
th
Gear
The input shaft drives Ravigneaux
planet small ring gear (5). The long
planet gears (PL2l) drive the short
planet gears (PL2k) to rotate inside the
large ring gear, which is held in place
by the B3 brake. This increases torque
and reduces rpm to the dual planet car-
rier (6).
The single rear planet ring gear (9)
rotates at the same speed as the dual
planet carrier, because theyre con-
nected mechanically. The planet gears
(PL6) rotate the sun gear (11), which in
turn rotates the sun gear (14) through
the K3 clutch.
Input torque and speed are trans-
mitted to the single front planet ring
gear (12) by the K2 clutch. The speed
difference between the sun gear (14)
and ring gear (12) produces increased
speed and reduced torque to the output
shaft through planet carrier (13).
The output shaft rotates with
reduced input speed in the direction of
engine rotation at a ratio of 0.73:1.
Power Flow; Reverse in S
Mode
The input shaft drives the
Ravigneaux planet small ring gear (5).
The long planet gears (PL2l) rotate
around sun gear (7), which is held by
the B1 brake. This transmits increased
torque and reduced rpm to the dual
planet carrier (6).
The single rear planet ring gear
(9) rotates at the same speed as the
dual planet carrier because theyre con-
Figure 6
0.82:1
GEARS August 2009 17
Figure 8
3.42:1
0.73:1
Figure 7
18 GEARSAugust2009
Mercedes 722.9 Preliminary Information; Part 3
Figure 9
nected mechanically.
The planet gears (PL6) rotate
around the sun gear (11). The sun gears
rotational direction is reversed by the
planet carrier (10), which is held by the
BR brake.
The applied K3 clutch connects
the sun gear (14) to sun gear (11). This
causes both sun gears to rotate at the
same speed and direction and drive
the planet gears (PL9). This increases
torque and reduces rotational speed to
the output shaft through the planet car-
rier (13).
The output shaft rotates at a reduced
input speed in the opposite direction of
engine rotation at a ratio of 3.42:1.
Power Flow; Reverse in
C Mode
The input shaft drives the
Ravigneaux planet small ring gear (5).
The long planet gears (PL2l) drive the
short planet gears (PL2k), which rotate
inside the large ring gear (8) as its
held by the B3 brake. This transmits a
decreased rotational speed to the dual
planet carrier (6).
The single rear planet ring gear
(9) rotates at the same speed as the
dual planet carrier because theyre con-
nected mechanically.
The planet gears (PL6) rotate
around the sun gear (11). The plan-
et carrier (10) reverses the rotational
direction of the sun gear, which is held
by the BR brake.
The K3 clutch connects the sun
gear (14) to the sun gear (11). This
causes both sun gears to rotate at the
same speed and direction and drive
the planet gears (PL9). This increases
torque and reduces rotational speed to
the output shaft through the planet car-
rier (13).
The output shaft rotates at reduced
input speed in the opposite direction of
engine rotation at a ratio of 2.23:1.
Thats all there is to it. By this time
you should have a good working under-
standing of the 722.9 transmission. And
as any good technician knows, under-
standing how it works is 90% of the
battle when it comes to diagnosing and
repairing a transmission.
2.23:1
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prec intl.indd 17 1/5/09 4:22:06 PM