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Home >> Mercedes Benz >> 1996 >> E320 >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Overhaul - 722 Series >> Transmission Reassembly

Transmission Reassembly

NOTE: During reassembly, lubricate bearing and valve body sliding surfaces with ATF. Soak new brake bands and clutch inner plates in ATF for at least one hour prior to installation.
  1. Place transmission case in holding fixture. Install guide ring and sealing ring in transmission housing. Sealing lip should face direction of brake band piston cover. Install "O" ring and radial sealing ring into selector lever shaft bores.
  2. Install screw-on plug and aluminum sealing ring. Install "O" ring in support flange bore of transmission case. Install Teflon rings on clutch K-2 support flange. Install support flange and tighten bolts to specifications. See TORQUE SPECIFICATIONS .
    NOTE: With brake band B-2 thrust element removed, the bore and tab on thrust element must align. With thrust element installed, one spring winding must be visible through the bore for lower cover oil pipe.
  3. Install brake band B-2 thrust element with tab in upward direction. Install thrust washer on support flange so that tab engages housing. Ensure Teflon rings on support flange are still in their grooves.
  4. Compress brake band B-2 by support tabs as much as possible and install. Brake band may be held in place with a snap ring. Install clutch K-2 on planetary gear set. While rotating input shaft, install planetary gear set assembly into case.
  5. Place transmission in a vertical position with input shaft pointing upward. Ensure planetary gear set is properly installed. Planetary gear set is properly installed when upper edge of connecting carrier is lower than supporting surface of brake B-3 outside plate. Install damping spring.
  6. Install brake B-3 clutch plates and compensating (spring) washer. See Fig 1. Place Parallel Bar (126589043100) on machined surface of transmission case. Place top of depth gauge on bar and tip of depth gauge on compensating (spring) washer. See Fig 2. Measure and record distance.
  7. Install gasket on front cover. Place parallel bar on top of brake B-3 piston. Place top of depth gauge on parallel bar and tip of depth gauge on gasket. See Fig 3. Measure and record distance.
  8. Difference between clutch pack depth measurement and piston height measurement is brake B-3 release clearance. Clearance should be .059-.079" (1.50-2.00 mm). Adjust clearance by changing thickness of brake B-3 outside plate(s).
    Fig 1: Installing Brake B-3 Clutch Pack
    G96D30869Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    Fig 2: Measuring Brake B-3 Clutch Pack Depth
    G93C25009Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    Fig 3: Measuring Brake B-3 Piston Height
    G93G25011Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  9. Coat groove(s) in input shaft with grease and install lubrication thrust ring(s). Diagonal cut on ring(s) must be held closed by grease. Install clutch K-1 while rotating it, so that splines engage. Engage lock assembly on brake band B-1. Install brake band B-1 with pin of lock assembly facing toward brake band B-1 thrust element.
  10. Install thrust pin and "O" rings into B-1 thrust element. Install thrust element and plug or overload protection switch into transmission case. Install brake band B-1 guide into transmission case bore. Ensure locating lugs engage in housing.
  11. On 722.3 and 722.4 Series transmissions, install gasket on front cover. Place parallel bar on clutch K-1 support flange. Place top of depth gauge on bar and tip of depth gauge on front cover gasket. Measure and record distance.
  12. Place parallel bar on machined surface of transmission case. Place top of depth gauge on bar and tip of depth gauge on clutch K-1 surface. See Fig 4. Measure and record distance.
  13. Hold shim, thrust washer, and bearing together. Using a vernier caliper, measure and record thickness of bearing assembly. See Fig 4. Clutch K-1 depth and thickness of bearing assembly subtracted from clutch K-1 support flange height equals clutch K-1 axial play. See CLUTCH K-1 AXIAL PLAY table. Adjust axial play by replacing shim. Shims are available in thicknesses of .004", .008" and .020" (0.1 mm, 0.2 mm and 0.5 mm).
    CLUTCH K-1 AXIAL PLAY

    Application Inches (mm)
    722.3 Series
    Rear Cover Removed .031-.047 (.80-1.20)
    Rear Cover Installed .016-.024 (.40-.60)
    722.4 Series
    Rear Cover Removed .024-.039 (.60-1.00)
    Rear Cover Installed .012-.020 (.30-.50)
    Fig 4: Measuring Clutch K-1 Axial Play (722.3 & 722.4 Series)
    G93H25012Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  14. On 722.3 or 722.4 Series transmissions, go to step 22). On 722.5 Series transmissions, ensure lubricating nozzle is installed and install thrust bearing. Lubricate overdrive brake piston "O" rings with ATF and press piston into transmission case. Install Teflon rings until seated into grooves. Install wave spring and overdrive brake piston snap ring.
  15. Install overdrive brake clutch plates and snap ring. Using feeler gauge, measure overdrive brake clutch plate clearance between top plate and snap ring. See Fig 5. Clearance should be .020-.043" (0.5-1.1 mm). Replace snap ring to obtain proper clearance.
  16. Place overdrive clutch assembly inside overdrive brake clutch plates. Install overdrive brake hub and sun gear. Install planet carrier gear with thrust bearing in place. Ensure thrust bearing does not move. Install original shims onto thrust bearing.
  17. Using depth gauge, measure distance between output shaft thrust bearing race and inner thrust bearing race. See Fig 6. Measure depth between shims and thrust bearing. See Fig 7. Using following formula determine shim thickness for correct axial play:
    • Shim Thickness =  "A" - "B" .004" (.100 mm)
    • "A" = Output shaft depth measurement.
    • "B" = Thrust bearing to shim measurement.
    • .004" (.100 mm) = Standard axial play.
      Fig 5: Measuring Overdrive Brake Clutch Clearance
      G96G30870Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
      Fig 6: Measuring Output Shaft Inner Thrust Bearing Race Depth
      G96H30871Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
      Fig 7: Measuring Intermediate Shaft Thrust Bearing Height
      G96I30872Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  18. Remove original shims and install shim(s) required to obtain standard axial play. Install output shaft and secure with snap ring. Install measuring disc and using depth gauge, measure between thrust bearing race inside rear cover and measuring disc. See Fig 8.
  19. Mount measuring disc and 3-arm flange onto intermediate shaft. Install plastic guide, parking lock pawl and spring. Engage parking lock pawl. Install flange nut and torque to 74 ft. lbs. (100 N.m). Install rear cover gasket onto transmission case. Using depth gauge, measure between gasket surface and measuring disc. See Fig 9.
  20. Use following formula to determine shim thickness for correct axial play between rear cover and output shaft:
    • Shim Thickness =  "A" - "B" .016" (.400 mm)
    • "A" = Rear cover thrust bearing depth measurement.
    • "B" = Output shaft height measurement.
    • .016" (.400 mm) = Standard axial play.
      Fig 8: Measuring Rear Cover Inner Thrust Bearing Race Depth
      G96J30873Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
      Fig 9: Measuring Output Shaft Height
      G96A30874Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  21. Remove flange nut, 3-arm flange and measuring disc. Replace shim with shim(s) required to obtain standard axial play. Install electrical plug for solenoid valves. Install rear cover, 3-arm flange and torque all bolts to specifications. See TORQUE SPECIFICATIONS .
  22. On all transmissions, coat Teflon rings on front cover with grease. Diagonal cut on rings must be held closed by grease. If necessary, remove rings and shape to a smaller diameter. Install front cover and gasket. Coat front cover bolt with non-hardening sealant and install.
  23. Rotate transmission so output shaft is pointing upward. Install snap ring on groove of output shaft. Install helical gear on output shaft (722.3 Series transmissions only). Install governor axial retainer. Install "O" ring and governor. Swivel axial retainer (if equipped) toward governor so it will enter groove of governor shaft. Install governor cover and snap ring. Pull cover out so it rests on snap ring.
  24. Install intermediate plate, "O" ring, and secondary pump. See Figure. Ensure governor axial retainer is properly seated and install nut. See Fig 10. Install oil pipe and bolt (if equipped).
  25. Install detent plate, linkage and shaft (or bolt). Mount roller on linkage and install plastic guide over roller. On 722.3 and 722.4 Series transmissions, install shim(s) on helical gear. Mount parking lock pawl, insert spring, and attach spring to pawl. Install parking lock gear.
    Fig 10: Installing Axial Retainer Nut
    G93I25013Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    NOTE: On 722.3 Series transmissions, use steps 26) through 28) to adjust output shaft end play. On 722.4 Series transmissions, use steps 29) and 30) to adjust output shaft end play.
  26. On 722.3 Series transmissions, install Measuring Sleeve (126589061400) over output shaft. Tighten output shaft nut to 74 ft. lbs. (100 N.m), engaging parking lock pawl to keep assembly from turning. Install rear cover gasket.
  27. Place parallel bar across rear cover gasket surface. Measure from top of parallel bar to flange of measuring sleeve. See Fig 11. Add .59" (15.0 mm) to measurement to compensate for parallel bar height and lip of measuring sleeve. Record measurement.
  28. Assemble rear cover. Measure distance from rear cover sealing surface to inner race of radial bearing. Subtract this measurement from measurement made in step 27) to obtain output shaft end play. End play should be .011-.020" (.30-.50 mm). Adjust end play by adding or removing shims under parking lock pawl.
    Fig 11: Measuring Output Shaft End Play (722.3 Series)
    G93J25014Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  29. On 722.4 Series transmissions, place Measuring Disc (129589062300) on rear cover surface. See Fig 12. Measure and record distance between measuring disc and ball bearing inner race. Install measuring disc and output shaft flange over output shaft. Tighten output shaft nut to 74 ft. lbs. (100 N.m), engaging parking lock pawl to keep assembly from turning.
  30. Install rear cover gasket. Measure and record distance between measuring disc and rear cover gasket. Difference between measurements is equal to output shaft end play. End play should be .008-.016" (.20-.40 mm). Adjust end play by adding or removing shims under parking lock pawl. Install helical gear on output shaft.
  31. On all transmissions, install mechanical speedometer oil pipe (if equipped). Install rear cover and washer on output shaft. Install "O" ring in output flange. Install output flange and tighten output shaft nut to specification. See TORQUE SPECIFICATIONS . Using a drift, stake collar of output shaft nut into groove of output shaft.
  32. Install kickdown solenoid. Install modulating pressure control valve and thrust pin. Install vacuum control unit (modulator) and retaining plate. Install starter lock-out switch, but DO NOT  tighten screws at this time.
    NOTE: Some models may have a modified vacuum modulator (identified by its plastic cover). If a customer complains of harsh upshifts, it is possible to reduce modulator pressure by 2.9 psi (.2 bar) by turning modulator cover counterclockwise all the way to end stop.
    Fig 12: Measuring Output Shaft End Play (722.4 Series)
    G93I25070Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  33. On 722.3 Series transmissions, install sealing ring on brake band B-1 piston, with lip pointing away from pin. Using assembly fixture, compress brake band B-1 piston, outer return spring and measuring plate. Install snap ring and remove assembly fixture. Turn measuring plate bolt by hand until resistance is felt.
  34. Turn measuring plate bolt with INCH-lb. torque wrench, and count number of turns required to tighten bolt to 9 INCH lbs. (1 N.m). With 9 INCH lbs. (1 N.m) torque, brake band travel should be .07-.08" (1.8-2.0 mm). Adjust brake band clearance by adding or removing shim(s) underneath thrust pin.
    NOTE: Measuring plate and screw have a 1-mm thread pitch, one turn on screw equals 1 mm of travel. For brake band pistons with removable thrust pin, use a bolt without measuring tip.
  35. On 722.4 Series transmissions, install sealing ring on brake band B-1 piston, with lip pointing away from pin. Using assembly fixture, compress brake band B-1 piston, both inner and outer return springs and measuring plate. Install snap ring and remove assembly fixture. Turn measuring plate bolt by hand until resistance is felt.
  36. Turn measuring plate bolt with INCH-lb. torque wrench, and count number of turns required to tighten bolt to 9 INCH lbs. (1 N.m). With 9 INCH lbs. (1 N.m) torque, brake band travel should be .07-.09" (1.8-2.4 mm) Adjust brake band clearance by adding or removing shim(s) underneath thrust pin, or install a brake band piston having a longer or shorter thrust pin.
  37. Install assembly fixture and remove brake band B-1 piston and measuring plate. Install brake band B-1 piston, return springs, shim(s), thrust pin and piston cover. Install snap ring and remove assembly fixture.
  38. Install thrust pin thrust element into brake band B-2 piston with large diameter toward brake band B-2. Install sealing ring and thrust pin on piston. Install piston in transmission, ensuring thrust pin engages brake band.
  39. Install brake band B-2 piston cover and snap ring. Push brake band support lug in direction of brake band piston until piston rests against piston cover. See Fig 13. Using vernier caliper, measure and record distance between support lug and brake band end.
    Fig 13: Measuring Brake Band B-2 Free Play
    G93J25071Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  40. On 722.3 and 722.4 Series transmissions, push brake band support lug toward thrust element. Measure and record distance between support lug and brake band end. Brake band B-2 clearance should be .216-.220" (5.5-5.6 mm). Adjust clearance by changing thrust pin. Thrust pin is available in lengths of 1.85-1.95" (47.2-49.6 mm) in increments of .030" (.8 mm).
  41. On all transmissions, insert brake band B-2 guide, one-way check valve, locating pin, temperature (throttle) restrictor, oil deflector, and filler piece (if equipped). Assemble lower cover and intermediate plate.
  42. Install lower cover and intermediate plate, ensuring oil pipe is positioned in bore. Center intermediate plate by means of 2 corner screws. Install and tighten remaining screws. Install leaf spring with bracket and tighten bolt.
  43. Install range selector lever, bolt and nut. Move range selector lever into Neutral and insert a .160" (4.0 mm) adjustment pin through range selector lever and into bore of starter lock-out switch. Tighten starter lock-out switch screws. Remove adjustment pin.
  44. Install valve body, ensuring range selector valve engages detent plate. Install and tighten valve body bolts. Install oil filter and attaching bolts. Install oil pan with NEW gasket.
  45. With selector lever in "N" position, check clearance between detent piston and stop on shift linkage. Adjust clearance to .016-.039" (.40-1.0 mm) by means of plastic clip. Plastic clip is available in 2 thicknesses.
  46. Check "O" ring on control pressure cable and replace (if necessary). Engage control pressure cable in connecting rod. Insert limiting rod into transmission housing and insert control pressure cable. Turn cable clockwise until it locks into place. Press sleeve of control pressure cable into housing. Turn sleeve clockwise until tab engages housing.
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