created 8 sep 2014 page 1 of 43 w220 2003 s500l diy...

Created 8th Sep 2014 of 43

W220 2003 S500L M-B Transmission 722.9 Transmission

DIY Flushing System With Fluid and Filter Service

Brian W. Rice

Condensed Table of Contents 1. Revisions ........................................................................................................................ 1

2. Relevance ....................................................................................................................... 1 3. Acknowledgment ............................................................................................................ 1

4. Reference ....................................................................................................................... 2 5. The Problem ................................................................................................................... 2

6. Warning.......................................................................................................................... 3 7. Identification of Transmission Pan Type ......................................................................... 4

8. Understanding the 722.9 Transmission Cooling System .................................................. 5 9. Location of 722.9 Transmission Cooling Lines ............................................................... 6

10. Direction of Flow 722.9 Transmission Cooling System................................................... 6 11. Design Of The DIY Transmission Flushing System ........................................................ 7

12. Important M-B Updates on 722.9 Transmission Servicing ............................................ 10 13. Parts Required for Fluid and Filter Service ................................................................... 10

14. Method Using DIY Flushing System (No TC Drain Plug)............................................. 10 15. Videos .......................................................................................................................... 31 16. Parts and Suppliers List ................................................................................................ 32

17. Conclusion ................................................................................................................... 43

1. Revisions Version 1 (Original document) Created 2014-09-08

2. Relevance My W220 2003 Update S500L (Long Wheel Base Sedan) has

Transmission: 722.9 (722 901 00 003 799) (7 forward and 2 reverse gears) (Build

Code 427 AUTOMATIC TRANSMISSION 7-SPEED),

Chassis Number: 220.175,

Engine Number: 113.960.

Note the seven-speed (722.9) is also referred to as:

NAG 2 {Neues Automatische Getriebe 2} New Automatic Gearbox 2 or

7G-Tronic

3. Acknowledgment BenzWorld Elite Members G-AMG and atmsmshr, and Member pinkster (Dean), and M-B

World’s Member, johnand (John Anderson)

This document draws on the contributions of G-AMG’s Photo DIY- 722.905 "7G Tronic NAG

2+ Transmission Oil/Filter Change”, John Anderson’s DIY write up of his service procedure

for his 2007 C230SS and pinkster’s home made flushing system. And the excellent videos

posted on YouTube by FixEuro.com and MrScott52.

http://www.benzworld.org/forums/44431-g-amg.html


4. Reference http://www.benzworld.org/forums/w221-s-class/1721569-photo-diy-722-905-7g-tronic.html

and

http://mbworld.org/forums/c-class-w203/365242-diy-722-9-7g-tronic-7-speed-automatic-

transmission-service-thread.html

and the excellent video of an automatic transmission fluid change and oil cooler flush.

https://www.youtube.com/watch?v=_-72EN_pqUU&feature=c4-overview&list=UU-

cOaimKXW9HqeSUQvBI2AA

5. The Problem In March of 2003, M-B released a bulletin, advising a one-time-only transmission fluid

change at 64,000Km (40,000 miles). This is to remove any particles that may have

accumulated during break-in.

Refer to: http://www.benzworld.org/forums/w220-s-class/1631656-transmission-service-

diy.html

The general consensus appears to be that it is a good idea to perform a regular transmission

flush and service every 3 years or 80,000Km (50,000 miles).

The 722.9 or 7G-tronic seven speed automatic transmission does NOT have a dipstick, so

checking fluid level via a dipstick is not possible. But, with a few quality tools a moderately

competent person can service their own 722.9 transmission and check the level themselves.

With the DIY Flushing System shown in this document it is a relatively straight forward task

and because the flushing process is powered by the vehicle's own transmission pump, the

dangers of over or under pressurising the system are eliminated.

If you have done work on the transmission or are just so inclined, a flush of the transmission

cooler with a commercial flushing agent is also possible. The methodology for this process is

not shown below.

Figure 1 Synthetic Transmission Cooler Flush

Be warned in advance that the fluid level is checked via an overflow method using a M-B

STAR Diagnostic System monitoring the fluid at a specified temperature.

5.1. Example of particles in filter. Refer to: http://www.youPipe.com/watch?v=7MX6FdPSJKA

http://www.benzworld.org/forums/w221-s-class/1721569-photo-diy-722-905-7g-tronic.html

http://mbworld.org/forums/c-class-w203/365242-diy-722-9-7g-tronic-7-speed-automatic-transmission-service-thread.html

http://mbworld.org/forums/c-class-w203/365242-diy-722-9-7g-tronic-7-speed-automatic-transmission-service-thread.html

https://www.youtube.com/watch?v=_-72EN_pqUU&feature=c4-overview&list=UU-cOaimKXW9HqeSUQvBI2AA

https://www.youtube.com/watch?v=_-72EN_pqUU&feature=c4-overview&list=UU-cOaimKXW9HqeSUQvBI2AA

http://www.benzworld.org/forums/w220-s-class/1631656-transmission-service-diy.html

http://www.benzworld.org/forums/w220-s-class/1631656-transmission-service-diy.html

http://www.youtube.com/watch?v=7MX6FdPSJKA


Figure 2 Examples of Particles in Transmission Filter

5.2. Secondary Issue

I discovered that the torque converter drain plug was removed from the 722.6 transmissions in

mid 1999 and that first generation 722.9 transmissions did not have one. It was reintroduced

later.

My 2003 (Update) W220 S500L with a first generation 722.9 transmission does not have a

torque converter drain plug, and the torque converter holds 4L of fluid which is nearly 50% of

the total capacity. Thus just draining the old fluid from the pan and not the torque converter

will severely contaminate any new fluid that is added. Flushing via the coolant lines seems to

be the only option in conjunction with a pan drop, filter change and refill via the overflow

tube, with a final setting of the correct fluid level using the overflow method and a STAR

DAS to monitor the fluid temperature.

Consequently I researched and designed a DIY flushing system which changes the fluid in the

torque converter and the transmission cooler.

6. Warning Reference G-AMG. “As a very Clear Preface... this job is not for the average DIY'er. It

requires a "Significant" number of Tools, including the STAR Computer, access to the

LATEST WIS, which is AN ABSOLUTE **MUST** IN ORDER TO CORRECTLY

ADJUST THE FLUID LEVEL!!!

Also, I will be *CLEAR*, there are MULTIPLE VARIATIONS of these Transmissions, you

MUST VERY VERY CAREFULLY Research your exact Transmission, to ascertain WHICH

procedure to use, and which Transmission FLUID to use. The latest transmissions use the

New 236.15 Spec Fluid which is BLUE!!!!! This Fluid is ***NOT*** Back-Compatible!!!

This Post is for a 722.905 NAG2+ Box in a 2011 E350 (212.056), which was built AFTER the

Latest/Greatest Update which was on June 21, 2010, so all vehicles after this date "Should"

have the Green Overflow Pipe, and Beveled Pan. Again, *YOU MUST BE 100% POSITIVE*

about your Transmission prior to starting the job.

ANOTHER *HUGE* CAVEAT!!- *DO NOT ATTEMPT THE "I'LL TAKE A LASER

TEMPERATURE MEASUREMENT OF THE PAN" TRICK TO GET THE OIL

TEMPERATURE!!!" I have a nice, High-End Fluke Laser Thermometer, and what I was

measuring at the Pan, and what STAR was Reporting. It was OFF by a much as 10°C!

***YOU MUST BE EXACTLY ON TARGET TEMP TO DO THIS JOB!***, and the Car

must be **LEVEL**, so you will have to have it on 4 equal Ramps/Jack-Stands.

As you know, there is NO Dipstick to check the Fluid Level, and you "Pump" the Oil *UP*

via the Drain-Hole. Instead, one needs to bring the oil Temp to a PRECISE temperature, and


"Visually" evaluate the Flow of Oil out the Overflow Pipe. What an IDIOTIC way to do an

automotive job!!! My "moderate flow" or "Drip pattern" may be waaaay different than the

next guy's interpretation. It's quite a "Joke" in my mind... BUT!! You must change the fluid in

these boxes, so you're STUCK!!

Over-Maintaining me, I'm doing the Service at 30,000 Miles (48,280Km), instead of the

Recommended 39,000 Mile (63,000Km) interval.

In summary, I intended this post to be "ENTERTAINMENT VALUE ONLY!!!!!!!" If you

Don't have the Proper Set-Up, DON'T DO THE JOB!!”

7. Identification of Transmission Pan Type Before proceeding, please verify that you have the new updated pan. If not, make sure you

have the updated pan in hand before proceeding.

Reference WIS document BT27.10-P-0006-01W: Oil pan and overflow tube modified

7.1. Summary of Transmission Pan Types

Early models use a non-bevelled pan with round indentations, a black overflow

pipe and use 236.12 or 236.13 fluid measured at 35°C.

Figure 3 Style of NAG1 (Early) Pan

From August 2003, the 7G-Tronic or 722.9 NAG2 updated pan has a bevelled or

sloping aft end with round indentations, a white overflow pipe and uses red 236.14

fluid measured at 45°C. This is my 2003 Update S500L type of pan.

Figure 4 Style of NAG2 Pan

For the updated bevelled pan with round indentations, the overflow pipe length was increased.

Figure 5 Changes in NAG1 and NAG2 Pans

After June 2010, the style of the 722.9 NAG2+ Pan has bevelled aft end with oval indentations and green overflow pipe and use blue 236.15 fluid measured at

TBD°C.


Figure 6 Style of NAG2+ Pan

8. Understanding the 722.9 Transmission Cooling System

Figure 7 722.9 NAG2 7G-Tronic Transmission Cooling System Schematic

All transmission fluid pumped from the pan goes through the filter first.

All the transmission fluid flows through the cooler unless the solenoid valve ‘AD’ operates

and bypasses fluid to the pan. The diagram shows it as a normally open valve. This means

there are two paths for fluid to return to the transmission pan;

1. via the AD solenoid and

2. via the transmission cooler in the radiator.

What causes AD to operate is not known. (My first assumption is that the Solenoid Valve AD

may have something to do with controlling the temperature of the transmission fluid during

warm up, normal operation and overload operation. I can envisage the Transmission ECU

monitoring the fluid temperature (we know that is has at least one temperature sensor as the

fluid must be at exactly 45°C for correct level setting using the overflow method) and using

the sensed value to divert the fluid so that it warms as quickly as possible. Above about say

80°C all fluid is most likely pumped through the transmission cooler located in the radiator.)

Because of the multiple return paths, installing a flush system in the transmission coolant

supply line will replace some dirty fluid but not necessarily all of it. If the solenoid valve AD

is open during the flushing process, some fluid will bypass the flushing system. Unfortunately


this doesn’t seem to be avoidable. In actual practice it doesn’t seem to be an issue either, as

the fluid being discharged from the transmission during a flushing procedure quickly became

pink in colour indicating little if no contamination with dirty fluid.

9. Location of 722.9 Transmission Cooling Lines The location of my transmission cooling lines are shown in the next diagram.

Figure 8 722.9 NAG2 7G-Tronic Transmission Location of Cooling Lines

10. Direction of Flow 722.9 Transmission Cooling System On the W220 S500L with 722.9 Transmission, the transmission cooler is located in the

radiator and is mounted vertically on the right side of the radiator as seen from the rear.

I confirmed the Transmission to Cooler Line which is connected to the Transmission Housing

on the right side and leaves the Radiator at the bottom right corner is the Return Line.

Consequently the Transmission to Cooler Line which is connected to the Transmission

Housing on the left side and enters the Radiator at the top right corner is the Supply Line.


Figure 9 722.9 NAG2 7G-Tronic Transmission Cooling System Direction of Flow

On my W220 2003 (Update) 722.9 Transmission the Transmission to Cooler Supply Line is in

two separate parts and has an intermediate in-line connector installed, see Blue Star in

diagram. My design utilises this convenient and easily accessible connection to install the

flushing system.

Figure 10 Supply Line Intermediate In-line Connection

11. Design Of The DIY Transmission Flushing System The design of the flushing system was based on the system suggested by BenzWorld Member,

pinkster (Dean) and my searching the Internet.

Most professional transmission fluid exchange machines use a bladder type system to hold the

new fluid (usually about 16L). In operation the old fluid flowing from the pump to the

transmission cooler is interrupted and the equipment inserted into the loop. The old fluid

supplies the hydraulic force to exchange the old fluid for the new. Sometimes they supplement

the pressure with a low pressure pump. The new fluid is returned to the pan, where it flows

through the filter first, then into the pump, valve body, torque converter etc.

My design opens the transmission to cooler supply line (left side) and using appropriate brass

couplings and reinforced vinyl hoses, connects in the home made flush system as shown. The


new fluid container is preloaded with say 4L of new transmission fluid and the old fluid

container captures the expelled fluid.

11.1. DIY Transmission Flushing System

The next diagram shows the DIY 722.9 Transmission Flushing System.

Figure 11 DIY Transmission Flushing System with 722.9 NAG2 7G-Tronic Connectors

11.2. DIY Transmission Flushing System Components

2 off 5L garden pressure sprayers.

1m 10mm O/D 6mm I/D rubber hose.

2m 10mm I/D reinforced clear vinyl hose.

Transmission intermediate connectors from a wrecked Mercedes-Benz vehicle.

Optional in-line transmission filter.

Hose clamps.

6mm – 10mm brass joiners.


11.3. Connection of DIY Transmission Flushing System

Figure 12 722.9 NAG2 7G-Tronic Transmission DIY Flushing System Connection Diagram

When the engine is started the transmission pump will push the hot and dirty fluid (BROWN

ARROW) from the transmission pan through the transmission filter, then the valve body

including the torque converter, and then into the Flushing System Dirty/Old Fluid Container.

The displaced air (WHITE ARROW) transfers to the Flushing System New Fluid Container

thus pushing the new clean fluid (PINK ARROW) through the Flushing System In-line Filter

and into the transmission cooler, then the return line (GREEN ARROW) and back into the

transmission pan.

No fluid is lost in the process.

The flushing should be stopped when the preloaded new clean fluid is nearly all consumed or

the colour of the discharged dirty/old fluid looks clean, the latter being the preference.


Figure 13 DIY Flushing System In Use

12. Important M-B Updates on 722.9 Transmission Servicing

Reference M-B WIS document AP27.00-P-2702W on how to service the transmission.

Note M-B changed a few things. They added:

Shifting the car into neutral before servicing.

A new filter gasket is required now and can NOT be reused.

Draining the torque converter is required as part of the service now.

13. Parts Required for Fluid and Filter Service See the detailed Parts and Suppliers List below.

14. Method Using DIY Flushing System (No TC Drain Plug) Print the next four pages as a guide for use during the Flush and Refill.

http://motors.shop.ebay.com/i.html?_nkw=torque+converter


14.1. Printable Summary of Method Using DIY Flushing System and Fluid Quantities Table

1. Shift transmission selector in Neutral with ignition off. 2. Get the car raised with the transmission pan level. 3. Remove the engine splash panel. 4. Layout plastic drop sheets under transmission pan and intermediate connector. 5. Find suitable containers for catching and storing at least 10L of waste fluid. 6. Have a pen and paper ready to record all fluid removed/replaced quantities. 7. Open the transmission to cooler supply line at the intermediate in-line connector and

catch the fluid. (Expect about 0.02L.) 8. Add 2L of new fluid into Flushing System New Fluid Pressure Container. 9. With the two Flushing System hydraulic lines connected together, prime output line

and in-line filter of flushing system with new fluid using hand pump in the New Fluid Container with any one air connection open. (Uses about 0.3L.)

10. Install the flushing system in the transmission to cooler supply line. 11. Bend over and clamp rubber inlet hose to Old Fluid container to prevent fluid going

back into Transmission. Use either Flushing System hand pump to pressurise both Old and New Fluid Containers. Observe the New Fluid Container level and allow 1L of new fluid to discharge into transmission cooler and return line. This flushes old fluid from the transmission cooler and return line into the transmission pan.

12. Remove the wiring brace at the front of the transmission pan and tuck the cables out of the way.

13. TAKE A PHOTO and carefully check the position and location of the pan bolts and sprags. (Front right corner has odd sprag with threaded bolt hole.)

14. Remove the transmission drain plug and catch the fluid. (Keep steady upward force on 6mm hex socket.) (Expect only a few drops of fluid.)

15. Dislodge the transmission overflow tube and catch the fluid. (Expect about 2 – 3L.) 16. Remove three pan bolts on right side. 17. Remove the three bolts on left side and catch the fluid. Keep pan level. (Expect about

1 - 2L.) 18. Remove the Transmission Filter and catch the old fluid. (Expect about 1 - 2L.) 19. Record the quantity of fluid collected during the pan and filter removal process. 20. TAKE A PHOTO and then remove white overflow pipe and magnets from inside

transmission pan. 21. Clean pan, and magnets. 22. Clean transmission gasket seat. 23. Install new filter. Listen for definite CLICK. 24. Reinstall magnets. 25. Install new white overflow tube. Notice a definite CLICK. 26. Install new pan gasket on cleaned pan. 27. Have six NEW transmission bolts and sprags ready. 28. Reinstall pan and while pushing the pan toward the rear, hand tighten bolts. 29. Torque each bolt in a cross pattern in stages to 4Nm (3 ft-lbf), then tighten each bolt

an additional 180°. 30. Reinstall the electrical connectors at front of pan. (Tucked away they touch the

exhaust.) 31. Calculate the quantity of oil removed so far. Will be about 7L. 32. Fill Assenmacher Refill Container with 5L new fluid. Record any fluid quantity

changes. 33. Attach adapter to pan.


34. Using Assenmacher pump in the initial quantity of fluid into the transmission pan. (The transmission should now have its original quantity of fluid but as a mixture of new fluid in pan and old fluid in torque converter.)

35. Shut off valve and leave the Assenmacher adapter, pump, and re-fill container in place.

36. Make sure Flushing System New Fluid Container contains about 4L of new fluid. Record any fluid quantity changes.

37. Use either hand pump to provide some initial pressure in both Old and New Fluid Containers. (Watch the level of the New Fluid Container as a guide as to how much pressure to add, ie pressurise until the level just starts to reduce.)

38. Flush Torque converter. Start engine and observe discharge of old fluid into the flushing system.

39. If necessary shut off engine to add a pause in the process. 40. When convenient place foot on brake and shift through "P-R-N-D" several times. 41. When the colour of discharge fluid appears clean or when the 4L of old fluid is

discharged and 4L of new fluid is consumed, stop engine. 42. It may be necessary to add more clean fluid and repeat until discharged fluid is clean.

Record any fluid quantity changes. 43. The transmission pan, torque converter and cooler should now contain close to 100%

new fluid. 44. Remove the flushing system. 45. Have pan drain plug and new crush washer ready for final installation. 46. Connect charger to car battery or charging point. 47. Connect STAR Diagnosis Assistance System to OBDII connector. 48. Using STAR, monitor transmission fluid temperature. (ECU/Electronic transmission

control (722.9 7G-Tronic)/Actual values/Oil level check/F2/010 Transmission oil temperature.)

49. Restart car engine and allow to idle in Park. 50. Shut off engine when fluid reaches 45°C. 51. Using Assenmacher pump in remaining fluid to make a total of 9.5L. Record any fluid

quantity changes. 52. Leave filler adapter in place and allow transmission to cool down to say 40°C. 53. Final Fluid Level Setting. Start the engine. DO NOT SHUT OFF THE ENGINE UNTIL

INSTRUCTED TO BELOW, ie only when fluid level is correct as below. 54. With engine idling and foot on brake, shift through "P-R-N-D" several times. 55. When the fluid temperature just reaches exactly 45°C remove the adapter filler. 56. Observe the quality of the fluid discharging from the drain plug aperture. 57. When only a small quantity of fluid dribbles out, reinstall the pan drain plug with a

new crush washer. Torque drain pan plug to 22Nm (16.5 ft-lbf). 58. Shut off the engine. 59. The transmission fluid is now at the correct level. 60. If no fluid was discharged when the transmission fluid temp reached the 45°C mark

(with engine idling and transmission in Park), then add more fluid and repeat the last few steps.

61. Measure quantity of fluid that dribbled out during level setting. 62. Clean any excess fluid off of pan and drain plug and reinstall underskirts etc.


Action Qty in

Assenmacher

Refill

Container

[L]

Qty in

Flushing

System

New Fluid

Container

[L]

Qty in

Flushing

System

Old Fluid

Container

[L]

Actual Qty

Into

Transmission

[+ In L]

Actual Qty

Out-of

Transmission

[- Out L]

Estimated

Transmission

Total

Qty

[L]

0. At Start

7. Open the transmission to cooler

supply line at the intermediate in-line

connector and catch the fluid.

8. Add 2L of new fluid into Flushing

System New Fluid Pressure Container.

9. Prime output line and in-line

filter of flushing system with new fluid

using hand pump in the New Fluid

Container

11. … flushes old fluid from the

transmission cooler and return line into

the transmission pan

11. … flushes old fluid from the

transmission cooler and return line into

the transmission pan

14. Remove the transmission drain

plug and catch the fluid.

15. Dislodge the transmission

overflow tube and catch the fluid.

18. Remove the Transmission Filter

and catch the old fluid.

32. Fill Assenmacher Refill

Container with 5L new fluid.

34. Using Assenmacher pump in the

initial quantity of fluid into the


Action Qty in

Assenmacher

Refill

Container

[L]

Qty in

Flushing

System

New Fluid

Container

[L]

Qty in

Flushing

System

Old Fluid

Container

[L]

Actual Qty

Into

Transmission

[+ In L]

Actual Qty

Out-of

Transmission

[- Out L]

Estimated

Transmission

Total

Qty

[L]

transmission pan.

36. Make sure Flushing System

New Fluid Container contains about 3L

of new fluid.

38. Flush Torque converter. Start

engine and observe discharge of old

fluid into the flushing system.

42. It may be necessary to add more

clean fluid and repeat until discharged

fluid is clean.

44. Remove the flushing system.

51. Using Assenmacher pump n

remaining fluid to make a total of 9.5L.

53. Final Fluid Level Setting.

After stopping the engine.

53. Final Fluid Level Setting.

After stopping the engine.

59. The transmission fluid is now at

the correct level.

61. Measure quantity of fluid that

dribbled out during level setting.

100. At end.

Table 1: Quantities of New and Old Transmission Fluids


14.2. Initial Preparation

Shift Transmission into Neutral and switch off ignition.

Use ramps, jacks, jackstands, etc to get the car up to a comfortable working height.

The transmission pan must be level in both the longitudinal and transverse axes. The easiest

way to verify level is by using a magnetic level on the transmission pan.

Layout plastic drop sheets under transmission pan and under transmission cooler intermediate

connector.

Find suitable containers for catching and storing at least 10L of waste fluid.

Have a pen and paper ready to record quantities of all removed old fluid and all replaced new

fluid. Record results on a print out of the Table of Fluid Quantities above.

14.3. Open the in-line connector and catch the fluid

Open the intermediate in-line connector in the transmission to cooler supply line and catch the

fluid.

Figure 14 Supply Line Intermediate In-line Connector

14.4. Prepare the Flushing System

Connect the Flushing System output connector to the input connector, ie create a closed loop

system.

Have about 2L of new fluid in the Flushing System New Fluid Pressure Container.

Figure 15 Flushing System with 2L New Fluid

With the two Flushing System hydraulic lines connected together, prime the output line and

the in-line filter of the Flushing System with new fluid using the hand pump in the New Fluid


Container with any one air connection open. Stop priming when new fluid starts to enter the

Old Fluid Container.) (Uses about 0.3L.)

Figure 16 Flushing System New and Old Fluid Containers after Priming Lines

Install the flushing system in the transmission to cooler supply line at the intermediate in-line

connection.

Figure 17 Flushing System Installed in Supply Line Intermediate In-line Connector

14.5. Flush transmission cooler and return line

Bend over and clamp the rubber inlet hose to the Old Fluid container to prevent fluid going

back into the transmission. Then use either hand pump to pressurise both Old and New Fluid

Containers. Observe the New Fluid Container level and allow 1L of new fluid to discharge

into transmission cooler and return line. This flushes old fluid from the transmission cooler

and return line into the transmission pan and ensures that the cooler and the return line contain

clean fluid before starting the transmission pan draining or the torque converter flushing

procedure.

Notice the dark colour of the discharged old fluid in the next Figure.


Figure 18 Flushing System after using transmission pump to flush transmission cooler and return line

Record the fluid levels in the Flushing System New Fluid Container and the Old Fluid

Container.

14.6. Remove Wiring Brace

Remove the wiring brace for the O2 sensor cables running across the front of the transmission

pan. Then unclip the connectors from the bracket holding them in place, and tuck the wiring

and connectors up out of the way.

Figure 19 Remove Wiring Brace at Front of Transmission Pan

14.7. Record Location of Pan Bolts and Sprags

TAKE A PHOTO and then carefully check the position and location of the pan bolts and

sprags before removing them. (Front right corner has an odd sprag with a threaded bolt hole.)

Rear right corner Centre right Front right corner


Rear left corner Centre left Front left corner

Figure 20 Location of Transmission Pan Bolts and Sprags Viewed from Underneath

14.8. Drain Transmission Fluid

Place a waste container under the transmission drain plug, and remove the drain plug with a

6mm Hex socket and ratchet. Around a litre or so of fluid will drain from the pan. Note the

6mm Hex drain is easy to damage unless a steady upward force is applied during removal.

Figure 21 Transmission Drain Plug 6mm Hex

Carefully collect all Transmission Fluid drained to be measured later.

Figure 22 Drain the Pan Fluid


Using the M-B drift or other suitable tool, pry the transmission overflow pipe off its seat in the

pan by inserting the drift through the drain plug hole in the transmission pan. About another 2

- 3 litres of fluid will drain out. The overflow pipe doesn’t need to come completely off its

seat. Just dislodged enough so the rest of the transmission fluid will drain out.

Figure 23 Dislodge the Old Overflow/Raiser/Level/Guide/Stand-off Pipe/Tube

Figure 24 Internal View of Overflow/Raiser/Level/Guide/Stand-off Pipe/Tube


Figure 25 Temporarily Reinstall the Old Drain Pan Plug Finger Tight to Stop Drips

Remove the three E10 torx bolts and sprags holding on the transmission oil pan on the right

side. Loosen the three E10 torx bolts and sprags on the left side. Carefully pull down on a

corner of the pan to release the pan from the transmission. Keep pan level.

http://www.benzworld.org/forums/attachments/w221-s-class/527472d1373948453-photo-diy-722-905-7g-tronic-21.jpg



Figure 26 Remove All Three Right Side Pan Bolts with E10 Torx

Figure 27 Loosen Three Left Side Pan Bolts with E10 Torx


14.9. Remove the Transmission Filter

Grab the transmission filter and pull straight down to remove from transmission.

Figure 28 Remove Old Transmission Filter (Pull Straight Down) and Collect More Fluid






14.10. Record the quantity of fluid after the pan/filter removal

Record the quantity of fluid collected during the pan and filter removal process.

14.11. Remove white overflow pipe and magnets from inside transmission pan

TAKE A PHOTO and then remove the white standoff pipe and the two magnets that sit on the

bevelled edge of the transmission pan.

Figure 29 Take Photo of Position of Magnets Before Cleaning

14.12. Clean Transmission Pan and Mating Surfaces

Remove and discard the transmission pan gasket.

Now reference G-AMG, “the most important part, cleaning. Thoroughly clean the

transmission pan, magnets, sprags, and pan mounting surface of the transmission. The sealing

surfaces of the pan and transmission housing must be absolutely free of any contaminates. Use

a quick flashing solvent to clean everything, like Brake Parts Cleaner, Isopropyl Alcohol,

Denatured Alcohol, etc. For good measure if you have compressed air, blow off the pan to

make sure no lint, etc is left behind.

I cleaned the NEW pan, NEW gasket, and transmission housing with a new microfiber cloth.

Tried the leather chamois, and it left a bunch of lint behind. So, after cleaning with the

microfiber I blew everything off with compressed air.”

Figure 30 Clean Transmission Pan Mating Surfaces



Figure 31 Remove Old Transmission Pan Gasket

Figure 32 Clean Transmission Pan

Figure 33 Clean The Magnets Inside The Transmission Pan

14.13. Install New Transmission Filter

Install the new transmission filter. Make sure the filter has a new o-ring installed. To install,

just position filter with standoff pointing up, and push into place. Listen for definite CLICK.




Figure 34 Install New Filter (Notice a Definite Click)

14.14. Reinstall New Transmission Pan

Note need to replace the cleaned magnets back into the bevelled side of the pan in the same

way you removed them.

Place a NEW overflow tube onto the inside of the pan above the drain plug hole. Be certain

the tube firmly snaps into place and the bottom of it is sitting flush on the pan. Notice a

Definite CLICK.

Figure 35 Install New Overflow Pipe (White or Green depending on Model) (Notice a Definite Click)

Place a NEW transmission pan gasket onto the pan. CAUTION: Do not apply any sealant or sealing compound to transmission oil pan or transmission housing.

Figure 36 Install New Transmission Oil Pan Gasket





Have the six NEW transmission bolts and the original sprags ready, then hold the transmission

pan in place, while inserting bolts through each sprag and hand tighten the bolts.

Figure 37Carefully Position All Sprags on Transmission Pan

Reference G-AMG, “I then proceeded to bolt up the pan. Here is where I think I screwed up

last time. There were 2 sprags, that weren't quite touching the transmission housing on the

outside edge before I pulled the pan. This time I was VERY careful in making sure all the

sprags were correctly seated on the pan. I did this by putting the two centre sprags and bolts on

loose enough just to hold the pan in place. Then I had to wiggle and push the pan toward the

rear of the car to get the pan and sprags to seat correctly. The rear of the pan gasket touches

the bracket for the transmission mount, and the gasket needs to be compressed slightly against

it. I noticed this the first time I put the pan up, but didn't push the pan toward the rear while

putting the sprags and bolts in, and remember the front two were a little difficult to hand

tighten the bolts. By pushing the pan toward the rear while hand tightening the bolts seemed to

work much better this time.

Can use automotive high tensile M6 x 1.0 x 40 45mm hex key bolts torqued to 12Nm (8.9ft-

lbf) as a temporary measure.

Once there are no leaks then the M6 bolts can be replaced with the genuine M-B one-use

ones.”

Figure 38 Remount Transmission Pan and Check Correct Alignment and Seating of All Sprags

Now using a torque wrench tighten the six bolts to 4Nm. Once all are tightened to 4Nm (3 ft-

lbf), then tighten each bolt an additional 180°.



Figure 39 Initial Tightening of Transmission Pan Bolts to 4Nm (3ft-lbf)

Figure 40 Final Tightening of Transmission Pan Bolts by Rotating a Further 180°

14.15. Reinstall the electrical connectors

Reinstall the electrical connectors back into place on the bracket in front of the transmission

pan and reconnect them.

14.16. Record Volume of Fluid Drained from Pan

Record the volume of fluid drained from pan.

14.17. Calculate the total quantity of fluid drained so far.

Calculate the total quantity of fluid obtained from the system so far using the printed record

table. Take into account that a small quantity may have been put back in during the initial

flushing of the return line.

14.18. Initial Filling Transmission with Fluid

Fill the Assenmacher Refill Container with new fluid to the quantity removed from the

calculation above.

http://viglink.pgpartner.com/mrdr.php?url=http%3A%2F%2Fviglink.pgpartner.com%2Fsearch_attrib.php%2Fform_keyword=automatic%2Btransmission&mt=~~~~~~~~n~~~




Figure 41 Refill set and adapter for Mercedes-Benz

Attach the Assenmacher Refill adapter (ATF 129) shut-off valve and hose to the pan.

14.18.1. Technique for Filling

The most important part is to always pump fluid in and try to pump as little air in the

transmission as possible.

Reference: Latest up to date M-B WIS document AR27.00-P-0270SYZ on filling the

transmission and checking fluid level.

Pump in initial quantity of fluid into the transmission pan.

Shut off valve and leave the adapter, pump, and bottle in place. (The transmission should now

have its original quantity of fluid but as a mixture of new fluid in pan and old fluid in torque

converter.)

Figure 42 Pump in 4L Transmission Oil Leave Filler Adapter in Place

14.19. Flushing Torque Converter and Cooler

Transfer attention back to the Flushing System. Make sure Flushing System New Fluid

Container contains at least 4L of new fluid. Record any fluid quantity changes.



Start the vehicle engine and observe the discharge of old fluid into the Flushing System

Old/Dirty Fluid Container. The discharge rate will be approximately 1L per 15 secs. Do not

let the Flushing System New Fluid Container run empty. If necessary shut off the engine to

add a pause in the flushing process.

When convenient place your foot on the brake and shift through "P-R-N-D" several times.

When the colour of the discharge fluid appears clean or when the 4L of new fluid is nearly all

consumed, stop the engine.

Record any fluid quantity changes.

It may be necessary to add more clean fluid and repeat until the discharged fluid is clean. This

is where I add the genuine M-B fluid. Record any fluid quantity changes.

The transmission pan, torque converter and cooler should now contain close to 100% new

fluid.

Remove the flushing system.

14.20. Setting Transmission Fluid Level

Have new pan drain plug and washer ready for final installation. The seal ring for the drain

plug must be replaced. The ring is a 12mm x 16mm x 1.5mm ring. Any standard copper

12mm sealing ring can be used.

Figure 43 Install New Sealing Ring on Pan Plug

Figure 44 Put Non-Hardening Sealant on Pan Drain Plug Washer

Connect charger to car battery or charging point.



Figure 45 Apply External Power

Activate STAR SDS and navigate to monitor transmission fluid temperature. (ECU/Electronic transmission control (722.9 7G-Tronic)/Actual values/Oil level check/F2/010 Transmission oil temperature.)

Figure 46 Connect STAR and Position Display to be seen from Under Vehicle.

Restart car engine and allow to idle in Park.

Figure 47 Observing Transmission Oil Temperature Start Engine and Run Until Oil Heats to 45°C.

Shut off engine when fluid reaches 45°C.





Pump in remaining fluid to make a total of 9.5L. Record any fluid quantity changes.

Figure 48 Pump in remaining fluid (to make a total of 9L) Leave filler adapter in place.

Leave filler adapter in place.

Start the engine. DO NOT SHUT OFF THE ENGINE UNTIL INSTRUCTED TO BELOW, ie

only when fluid level is correct as below.

With the engine idling and your foot on the brake, shift through "P-R-N-D" several times.

Figure 49 Start engine and cycle through all gears (with foot on brake)

Figure 50 Don’t forget to include reverse gear (with foot on brake)

Allow engine to idle in selector lever position "P". ie keep the engine running.





Call up the transmission fluid temperature Transmission oil temperature using STAR

DIAGNOSIS.

While watching the transmission temperature via STAR, wait until the temp reaches just under

45°C/113°F.

Figure 51 Allow transmission to warm to exactly 45°C.

The engine must run at idle speed and the transmission oil temperature must not be above the

specified transmission oil temperature as too much transmission oil is drained at a higher

transmission oil temperature.

Quickly get under the car and remove the filler adapter and allow the excess fluid to drain out

until a small quantity still drains out. Keep checking the temperature and make sure the flow is

correct when the temperature is exactly 45°C (exactly and not over or under).

Figure 52 Over Filled Appearance – Strong Steady Stream




Figure 53 Correctly Filled Appearance –Sputtering/Broken Flow Almost Just Dripping

Figure 54 Reinstall Pan Drain Plug with New Washer and Torqued to 22Nm

Then reinstall the transmission pan drain plug and tighten to 22Nm.

The transmission fluid is now at the correct level.

Shut off the engine.

If the fluid flow is not constant after opening the filler adapter, the transmission fluid level has

to be corrected and then adjusted again, ie pump in more transmission fluid using the fluid

dispenser and the filler adapter. Then retest the level at exactly 45°C as before.

The transmission is now at the correct level.

14.21. Final Steps

Clean any excess fluid off the pan and drain plug.

15. Videos There are several videos on the Internet with relevance.

www.youPipe.com/watch?v=7MX6FdPSJKA

http://www.youtube.com/watch?v=7MX6FdPSJKA




www.youPipe.com/watch?v=pFgfHkK_FsY

www.youPipe.com/watch?v=3t2_U9POygQ

16. Parts and Suppliers List

16.1. Parts Needed

16.2. Summary of Parts Needed

Part M-B Part# Supplier Part# Qty

Transmission Service Kit

9L M-B Fluid

2212770195 2212770195KT1

ES#2696244

1

Transmission Service Kit

9L Febi Fluid

2212770195 2212770195KT2

ES#2696245

1

M-B Transmission Fluid 0019896803 ES#1887653 1L

Fuchs Transmission Fluid 0019894503 Titan ATF 4134

Sprint 4072004

4L

Filter 2212770195 1

Pan Gasket 220-271-03-80 1

http://www.youtube.com/watch?v=pFgfHkK_FsY

http://www.youtube.com/watch?v=3t2_U9POygQ


Part M-B Part# Supplier Part# Qty

Pan Bolts Genuine M-B 0049903512 ES#1617931 ea

Transmission Drain Plug

Transmission Drain Plug Washer 007603-012102 1

Overflow Pipe White Genuine M-B 2512710097 ES#1805949

1

Torque Conv Drain Plug with washer 001 990 11 17 ES#1613928

Drift/Mandrel 7225890315 1

Filler Kit with M-B Adapter Assenmacher

Specialty Tools

ATF 1004-5 M-B

1

16.3. Transmission Service Kit Description

Manufacturer Part Number: 2212770195

16.4. Transmission Service Kit Suppliers

16.4.1. ECS Tuning

http://www.ecstuning.com/Search/SiteSearch/2212770195/

16.4.2. eBay Seller specindustries

http://www.ebay.com.au/itm/MERCEDES-BENZ-722-9-TRANSMISSION-SERVICE-KIT-SHELL-ATF-134-

AMG-OEM-PARTS-

/111240001460?pt=Motors_Car_Truck_Parts_Accessories&hash=item19e66bb7b4&_uhb=1


http://www.ebay.com.au/itm/MERCEDES-BENZ-722-9-TRANSMISSION-SERVICE-KIT-SHELL-ATF-134-AMG-OEM-PARTS-/111240001460?pt=Motors_Car_Truck_Parts_Accessories&hash=item19e66bb7b4&_uhb=1




Manufacturer Part Number: 2212770195

Other Part Number: 0049903512, 007603-012102, 2202710380,

2512710097

Mercedes Benz 722.9 transmission service kit. This kit comes with RED fluid and applies

to vehicles manufactured up to June 2010 that are equipped with the 722.9, 7 speed transmission. Not sure if this fits your vehicle? Check the production date sticker in your door jamb, call your local Mercedes dealer with your VIN number or email us your vehicle specs. This kit includes;

9 quarts (8.52L) of Shell ATF-134

1 OEM transmission filter; part number 221-277-01-95

6 transmission drain pan bolts; part number 004-990-35-12

1 transmission drain plug crush ring; part number 007603-012102

1 transmission pan gasket; part number 220-271-03-80

1 transmission pan guide Pipe; part number 251-271-00-97 Need additional quarts of ATF-134? Let us know, we can customize this kit for you!

16.4.3. eBay Seller Parts Pro

eBay Service Kit (Without Transmission Fluid) http://www.ebay.com.au/itm/Genuine-OEM-Mercedes-Benz-722-9-Transmission-Service-Kit-

/331090662334?pt=Motors_Car_Truck_Parts_Accessories&hash=item4d168a93be&_uhb=1

http://www.ebay.com.au/itm/Genuine-OEM-Mercedes-Benz-722-9-Transmission-Service-Kit-/331090662334?pt=Motors_Car_Truck_Parts_Accessories&hash=item4d168a93be&_uhb=1

http://www.ebay.com.au/itm/Genuine-OEM-Mercedes-Benz-722-9-Transmission-Service-Kit-/331090662334?pt=Motors_Car_Truck_Parts_Accessories&hash=item4d168a93be&_uhb=1


Genuine OEM Mercedes Benz 722.9 Transmission Service Kit - TRANSMISSION FILTER # 221-277-01-95 - TRANSMISSION GASKET # 220-271-03-80

- DRAIN PLUG SEAL # 007603-012102 - 6 TRANSMISSION PAN BOLTS # 004-990-35-12 - TRANSMISSION LEVEL PIPE # 251-271-00-97

16.5. Transmission Fluid

16.5.1. Quantity

9.7L = 10.2Quarts

16.5.2. Description

Transmission fluid required is ATF 3353 M-B Part Number A001 989 45 03 10 or A 001 989 68 03 Latest Spec says 236.14


Refer to the latest WIS document BB00.40-P-0236-14A on approved ATF.

16.5.3. Brands Fuchs Titan ATF 4134 Fuchs Petrolub AG, Mannheim, Germany Fuchs Titan EG ATF 134 Fuchs Petrolub AG, Mannheim, Germany M-B 236.14 ATF NAG2VSport A 001 989 68 03 Daimler AG, Stuttgart/Germany

Mercedes-Benz automatic transmission oil sheet 236.14 Daimler AG, Stuttgart/Germany Mercedes-Benz transmission oil sheet 236.14 Daimler AG, Stuttgart/Germany Mobil ATF 134 Exxon Mobil Corporation, Fairfax, Virginia, USA

Shell ATF134 Shell International Petroleum Company, LONDON, UNITED KINGDOM Shell SPIRAX S6 ATF134M Shell International Petroleum Company, LONDON, UNITED KINGDOM Q8 AUTO 25 Kuwait National Petroleum Company, Kuwait

16.5.4. Fuchs Titan ATF 4134

Available as 1L or 4L

In Australia available from Sprint Auto.

16.1. Transmission Filter

16.1.1. Description

A 221 277 01 95 or A 221 277 01 98


16.1.2. Supplier

Supplied as part of ECS Tuning Transmission Service Kit or separately as;


http://www.ebay.com/itm/Mercedes-Benz-Transmission-Filter-Gasket-Kit-Hamman-OEM-

Quality-722-9xx-

/400384931935?pt=Motors_Car_Truck_Parts_Accessories&vxp=mtr&hash=item5d38cd385f

16.2. M-B Filler Adapter 12mm x 1.5

16.2.1. Description

12mm x 1.5 Mercedes-Benz adapter for the 722.9 Automatic Transmissions. Used in

conjunction with the ATF Filler System. Comes separately or as part of a Filler Kit.

Assenmacher Specialty Tools Inc. 722.9 Drive Line Filler Adapter Part Number ATF 129

16.2.2. Suppliers

Comes separately as Mercedes Drive Line Filler Kit Assenmacher Specialty Tools Inc. Part

Number ATF 129.


http://www.ebay.com/itm/Mercedes-Benz-Transmission-Filter-Gasket-Kit-Hamman-OEM-Quality-722-9xx-/400384931935?pt=Motors_Car_Truck_Parts_Accessories&vxp=mtr&hash=item5d38cd385f




Or as part of a Filler Kit Part Number ATF 1004-5 M-B see below.

http://asttool.com/detail_page.php?from_search=y&tool_number=ATF%20129&total=59&off

set=27&stype=bymanf&manf=Mercedes

16.3. Fluid Filler Kit

16.3.1. Description

Used for filling fluids in the 722.9 Automatic Transmissions using a 12mm x 1.5 adapter.

16.3.2. Special Mercedes Drive Line Filler Kit Description

Used for filling fluids in the 722.9 Automatic Transmissions using a 12mm x 1.5 adapter. (not

suitable for use with fuels or solvents). ATF 1004 M-B set includes pump, container, hose,

shut-off valve and the following adapters: ATF 129 (applicable to Mercedes).

16.3.3. Suppliers

http://www.costplustools.com/Assenmacher-ATF1004-5-M-B-Mercedes-Drive-Line-Filler-

_p_14869.html

16.4. Transmission Oil Pan Gasket

16.4.1. Description

A 220 271 03 80

http://asttool.com/detail_page.php?from_search=y&tool_number=ATF%20129&total=59&offset=27&stype=bymanf&manf=Mercedes

http://asttool.com/detail_page.php?from_search=y&tool_number=ATF%20129&total=59&offset=27&stype=bymanf&manf=Mercedes

http://www.costplustools.com/Assenmacher-ATF1004-5-MB-Mercedes-Drive-Line-Filler-_p_14869.html

http://www.costplustools.com/Assenmacher-ATF1004-5-MB-Mercedes-Drive-Line-Filler-_p_14869.html


16.4.2. Suppliers


16.5. Transmission Overflow Pipe

16.5.1. Description

Transmission Guide Pipe or Overflow Pipe Clips onto Pan above Drain Plug.

A 251 271 00 97

16.5.2. Suppliers



autohaus



16.6. Transmission Drain Plug

16.6.1. Description

16.6.2. Suppliers

Supplied as part of ECS Tuning Transmission Service Kit

16.7. Transmission Drain Plug Sealing Washer (Crush Ring)

16.7.1. Description

N0077603012102

The seal ring for the drain plug must be replaced. The ring is a 12mm x 16mm x 1.5mm ring.

16.7.2. Suppliers


Any standard copper 12mm sealing ring can be used. These can be had at most hardware

stores. If you plan on doing a few changes, pick up the 25pack from McMaster Carr.

16.8. Transmission Pan Bolts (6 off)

16.8.1. Description

A 004 990 35 12 or 220.175 5 0 Transmission Pan Bolt - (6 x 40 mm) Mercedes-Benz S500

2004 Base Sedan

The six aluminium Transmission Pan Bolts must be replaced after removal.


16.8.2. Suppliers


Or


http://www.rmeuropean.com/Part-Number/Transmission-Pan-Bolt-%286-x-40-mm%29-%286-Per-Car%29-__0049903512_GEN_5C1313F8.aspx

16.9. Drift/Mandrel Special Tool

16.9.1. Description

Used to release Overflow Pipe to allow fluid to drain before removing the pan.

722 589 031 500





16.9.2. Suppliers


http://mbspecialist.be/nl/mercedes_webcatalog/item/722589031500/?utm_source=mbspecialis

t.com&utm_medium=website&utm_content=webcatalog&utm_campaign=Partners

12EU

16.10. Torque Converter Drain Plug

16.10.1. Description

Drain plug for torque converter is 4mm allen. A 001 990 11 17

16.10.2. Suppliers


http://www.ecstuning.com/ES1613928/


http://mbspecialist.be/nl/mercedes_webcatalog/item/722589031500/?utm_source=mbspecialist.com&utm_medium=website&utm_content=webcatalog&utm_campaign=Partners

http://mbspecialist.be/nl/mercedes_webcatalog/item/722589031500/?utm_source=mbspecialist.com&utm_medium=website&utm_content=webcatalog&utm_campaign=Partners

http://www.ecstuning.com/ES1613928/


16.11. Cleaning and Degreasing Product

16.11.1. Description

LOCTITE® Product 7063 is a non-CFC solvent based formulation for cleaning and

degreasing of surfaces to be bonded with Loctite adhesives. The product is HIGHLY

FLAMMABLE. It may be used as an alternative to 1,1,1 -Trichloroethane.

LOCTITE 7063 is recommended as a final preassembly cleaning treatment for all surfaces to

be bonded with Loctite anaerobic adhesives. Because of its high solvent power it is also very

effective in other degreasing or part-cleaning applications.

Figure 55 LOCTITE® Product 7063

17. Conclusion Was it worth doing this project?

Was it ever! The transmission now has superbly smooth changes and considering the very

dark colour of the fluid that was removed, changing to new fluid should improve the longevity

of the transmission.

created 8 sep 2014 page 1 of 43 w220 2003 s500l diy...

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