722.6 tranny problem - Mercedes-Benz Forum
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post #1 of 15 (permalink) Old 10-18-2012, 04:58 AM Thread Starter
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722.6 tranny problem

*Car:
Mercedes W210 E240 year 2001
Transmission: 722.6

*Description of tranny 722.6 Problem:
- upShift 1-2: OK
- upShift 2-3: Revs high, and could not shift to 3 then go to error 2503 "implausible"
- It happened sometimes: delay engagement, not engangement (drives like at a neutral)
* What I did
- Changed ATF 4 or 5 times. ATF color was brown, my tech says it is a clutch abrassion, there is no shavings.
- Check the plug: still fine
- Check the electronic plate, check 2 speed sensors: Still good. But it was reading "0" sometimes (checked by DAS)
* Error Code (read by DAS)
- Always 2503
- Sometimes 2502

Your contribution is highly appreciated!
Thanks
Mark

Last edited by w210e63; 10-18-2012 at 11:32 AM.
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post #2 of 15 (permalink) Old 10-18-2012, 05:07 AM
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Mark, I'm no whiz kid on MBs and MB sure makes it tough for the DIY guy to get info but I have read that the seal of the electrical cable going into the tranny has a tendency to allow oil to leak onto the control modulator. Your symptoms sound like that could be the cause. If it is, change the seal. The control module might be salvage if you dry it off. That's all I can offer.
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post #3 of 15 (permalink) Old 10-18-2012, 11:42 AM Thread Starter
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thanks
control module you said means EGS? could you show me where the "electrical cable going into the tranny" is.
much thanks
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post #4 of 15 (permalink) Old 10-18-2012, 05:38 PM
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Mark,

Welcome to the forum, and I imagine you are not in the USA as the result of your E240. Fill out your profile.

Getting back... I have some questions for you.

1) Shifting from 1 to 2 okay, and shifting 2 to 3 not okay(sometimes) what about the other gears?

2) "Drives like in Neutral" I never though I could not accelerate from neutral, so what you are saying it goes into neutral? during the shift of 2 to 3, correct?

3) what about the other gears after the shift of 2 to 3 ?

4) How long was the time between the last transmission fluid change to when you started having problem.

5) Lucky 5, five times!! How long were the fluid change intervals in between these 4 to 5 times? To get ALL the fluid out. You need to do a fluid exchange to get all of it as the 2000+ 722.6's have not torque converter drain plug. On E320's this is how you get all the fluid out, see post 11:

https://www.benzworld.org/forums/w210...ml#post5406702

What I would do is what is outlined in post 2. Check the Transmission Computer for intrusion of transmission fluid as the fluid will "wick-up" the transmission electrical control cable and make it up to the transmission computer. If you find fluid at the top in the Transmission Computer area, you will need to remove the computer(disconnect the battery) and clean it with electronic contact cleaner. Clean the connector too. Allow everything to dry completely before assembling.

Look in the stickies section for the replacement of the transmission connector and the o-ring if you find fluid in the Transmission Computer. Buy a factory new part from the actual dealer, no aftermarket parts!!!

Now, my guess providing no fluid is found up in the Transmission Computer area. To check the resistance of the shift solenoids since it is an easy test to do. The test is performed at the transmission computer connector at the computer area. You need an ohm meter, see P23 attachment.

Now, if the fluid has just come out brown in all the fluid changes then the clutch packs are just worn-out, and your transmission needs to be rebuilt. The transmission has nothing to grab onto, so it is just slipping?

The 2-3 shift is the Achilles heal with all 722.6's. You could have the solenoid not working right, not making good contact, 2-3 piston(very worn-common), spring in the valve is worn or broken, pressure regulator valve can cause this, but you have problems in all gears. THE BROWN fluid will not be affected by anything in the valve body. I would swap the 2-3 shift solenoid with the 3-4 solenoid-see the 722dot6 document.

The valve body is heavy and must be torqued-on. Here is a video of valve body update. I would buy this Sonnax kit, but it will give you some insight.



I just did a fluid-exchange on 722.6 S500 two months ago The fluid had never been changed in the life of the car, and the car had 185k Miles, and after four-gallons(15 liters) of fluid. The car shifted excellent, but before the car would slip in all gears, and the fluid came out chocolate-brown.

Let us know what happens.

Best of luck,

Martin
Attached Files
File Type: pdf p23.pdf (57.1 KB, 1192 views)
File Type: pdf 722dot6 valvebody layout.pdf (40.9 KB, 1131 views)
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post #5 of 15 (permalink) Old 10-19-2012, 04:51 AM
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Good advice from Martin.

Some other thoughts:

Did the tranny work prior to the ATF flushes?

Is this a replacement tranny?

Has the ATF level been verified to be within high and low marks on dipstick with engine running?

Was MB approved ATF used?

What was done to 'check' the adapter plug? There are 2 O-rings, and an inner O-Ring leak will not be detected externally, but will wick up into the TCU.

Good Luck - keep at it.
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post #6 of 15 (permalink) Old 10-22-2012, 09:15 PM Thread Starter
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@MAVA:
Yes. I have already updated my profile. I am living in Vietnam
1) Q: Shifting from 1 to 2 okay, and shifting 2 to 3 not okay(sometimes) what about the other gears?
A: The ETC seem to manage to upshift from 2 to 3 without success. Firstly: (target gear =3, actual gear =2);secondly: (target gear=still 3, actual gear =3 and immediately down to 2); finally: (target gear = implausible, actual gear = implausible). Pls see attachments regarding to the error.
2)Q: "Drives like in Neutral" I never though I could not accelerate from neutral, so what you are saying it goes into neutral? during the shift of 2 to 3, correct?
A: A month ago it happenned as above 1). then I stopped the car and restart engine, error code was cleared, it was running around a haft of mile and "implausible" again.
I had repeated: (restart, run till "implausible") then maybe error count reached a limitation value then my car was running at Emergency Mode (Limp mode). I was trying to drive my car to a garage, and after around 1/3 mile, engine running as in neutral gear (transmission was not engaged, rev is very high)
3) Q: what about the other gears after the shift of 2 to 3 ?
A: It is an "Implausible" gear as displayed on the Star diagnotic program.
4) Q: How long was the time between the last transmission fluid change to when you started having problem.
A: Actually I bought this car on April of 2012 (odometer was 50000miles), I dont really know what was the last fruid change. It was running fine till I felt weird while accelerating, transmission was shifted not so smoothly. I brought my car to the garage and changed the oild filter and transmission fruid which was brown, something like a brown mud in the gasket (no shaving). After a week, I changed the oil fruid again and it is still brown... and changed again more 2 or 3 times, now it is still brown.
5)Q: Lucky 5, five times!! How long were the fluid change intervals in between these 4 to 5 times?
A: It was about a week btw the changes

+)I will check the Transmission computer area and following the guidelines of changing fruid at https://www.benzworld.org/forums/w210...ml#post5406702 then let you know what happens.

@atmsmshr:
Yes it was running nicely before
No. It is an original tranny
Yes. ATF verified and I tried many level of fruid for testing
I will check again with 2 O-rings

Thanks
Mark
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Last edited by w210e63; 10-22-2012 at 09:19 PM.
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post #7 of 15 (permalink) Old 10-25-2012, 02:11 AM Thread Starter
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Any help?
Thanks
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post #8 of 15 (permalink) Old 10-27-2012, 06:05 AM
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Its good that you have verified the correct ATF and level with the engine running and car in park. Those are the easy checks.

In level of increasing difficulty (IMHO) for diagnostics:
1) Was the trans filter replaced during ATF oil change?
2) Is there a leak past the first O-ring on the adapter plug?
3) Is there fluid in the TCU (wicked up through adapter plug)?
4) Are the electrical checks in MAVA's post ok?
5) Disassemble and inspect the valve body.

Attached is the STARTEK troubleshooting guide.
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File Type: pdf Transmission Troubleshooting Guide.pdf (78.4 KB, 1061 views)
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post #9 of 15 (permalink) Old 11-01-2012, 04:39 PM
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Mark,

Pardon the delay, but I lost my internet in my area, and I'm back up and running!

What I would do? Swap out 2-3 solenoid with 3-4 solenoid. and, I would inspect 2-3 valve body piston & spring; Inspect regulating piston and Spring too, yet to do these tests you will need to bring the valve body down.

Since the valve body will be out, I would just inspect every valve and valve-spring, but it really is sounding like a clutch(s) is just worn-out.

Martin
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post #10 of 15 (permalink) Old 11-01-2012, 09:43 PM Thread Starter
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Originally Posted by MAVA View Post
Mark,

Pardon the delay, but I lost my internet in my area, and I'm back up and running!

What I would do? Swap out 2-3 solenoid with 3-4 solenoid. and, I would inspect 2-3 valve body piston & spring; Inspect regulating piston and Spring too, yet to do these tests you will need to bring the valve body down.

Since the valve body will be out, I would just inspect every valve and valve-spring, but it really is sounding like a clutch(s) is just worn-out.

Martin
Hi Martin
Thanks for your help.
I am working with EGS (TCM) double checking. I found EGS fully filled with oil. I though there is NO OIL in original EGS?
Thanks
Mark
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