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E55 722.643 Transmission Rebuild PICS

 
Old 07-31-2011, 06:18 PM
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Talking E55 722.6 Transmission Rebuild PICS

Well, this all started with a leak from the front trans seal and after pulling the transmission from the car it was easily DX as a bad front pump bushing which had spun in the housing. This is what the torque converter rides on and when worn/spun it allows too much fluid to enter the front which the seal and drain hole cannot accommodate resulting in leakage.

Now, Mercedes of course does not source just the bushing. I was able to source a heavy duty Sonnax bushing in hope that it would solve the issue. Though it fit snug, it was not a right tight fit and this is where one of many forward thinking decisions had to be made. I could have used Loctite Green Sleeve retainer which may have worked to secure the bushing, but.................you know how that goes. This is not an old Dynasty or Escort, I want this done correctly which means the trans pump must be replaced. Also, Sonnax does sell an over-sized bushing for situations such as this, but the housing must be machined. Why bother..........

Unlike earlier MB transmissions, the 722.6 front pump does not come out the front..well, it does, just the bolts to release it are located on the inside necessitating opening the case. The pump for many transmissions including the 722.4, domestics, etc have the pump bolts accessible from the outside making things so much easier. Remove bolts, pull out pump, swap, have a great day-just not in this case.

Decision time again, as I must crack the case on this transmission, and though the bolts are easily removed once the front is removed, the gasket is not requiring removal of the B-1 clutch housing. So the mind goes to work. Case is open, already inside the thing, might as well rebuild the trans with new bushing, bearings, seals, frictions plates, etc.....Makes sense anyhow. Right? Imagine the frustration if later the trans starts to slip and it was something I could have remedied while it was open.

This is work in progress. The car is not my daily driver, far from it, so time is on my side, and as so many have learned before, rushing results in problems.

I will update the thread as time goes, but here are a few photos to share today.

Keep in mind there are variations of the 722.6 transmission with double sided friction, single sided, qty of friction, size of friction,etc..

The E55 W211 uses the 722.643 version with SINGLE SIDED friction. 8 qty alone just on the front B-1 housing.

NOTE: If you do not have the space, the time, the tools, the patience, do not attempt at home. You can get a rebuilt trans with warranty for $1800 or so-though who knows what really gets rebuilt.....or buy a brand new one for $7k from MB. Also, this is NOT a DIY thread. There is simply too much involved. But if someone had questions, feel free to ask.

My goal here is to rebuild the internals which are not easily accessible unless the transmission is removed and opened. Items such as valve body, conductor, solenoids, etc can be worked on with the transmission in the car. Also remember, the transmission performed fine apart from the leak. If a solenoid goes bad later, big deal, drop pan, get dirty replace.

Opening and inspecting the transmission resulted in a very clean and well conditioned transmission. It really is in great condition. Minor shavings in pan were from the bushing and nothing more. Needle bearings, plates, everything looks like a 20k car and not something approaching 100k miles. Truly great engineering considering how much I beat it. Nice job AMG!

OK, so on to some pictures.



On the trans jack. Awesome jack which I welded some side 'anchors' to avoid any side to side movement. I have used this on my Lexus trans as well. Available at Harbor Freight for cheap.




Front pump. There should be a bushing in the middle-removed. Actually, it fell out. LOL. Look carefully enough at the housing under the shaft and you will see what should be smooth. Not.


Checking for endplay gives me an idea of what I might find. All good.



The legendary for leaking connector. Always replace this. Bought this for $10.00 new. If allowed to leak it could wipe out your transmission ECU.




B-1 Clutch Housing. Notice the friction discs in there? There are both external and internal friction plates with only the later visible. Remember, these are single sided on this car. The bolts in the middle secure the front pump, but in order to replace the 'intermediate plate'/gasket, the whole thing must come apart, piece by piece.



K1-K2 clutch assembly


Close-Up of K-1 housing



K-1 and B-1 housing




Friction Plate from the B-1 housing. Everything actually looked decent, however if you look carefully enough, in the middle, you will see a wear patch. A few plates have this and I'm just not that comfortable with it. Whereas specs call for 2.07mm plates, mine are at 2.05mm which may be good for some, but not me. Keep in mind this transmission exhibited no issues other than the leak. It shifted and grabbed gears with no issues.

Last edited by pearlpower; 08-01-2011 at 03:45 PM.
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Old 07-31-2011, 06:20 PM
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Part II

I have well over 300 sockets of various sizes, types, etc. But of course, not a 30mm DEEP 12point. OK, need to Easter hunt for one.




With the bad comes some good and accessibility to other areas is greatly improved with the transmission removed. The rear main seal just begging me to show it some attention, and it needed it. Even though this was already replaced by the dealer 25K miles ago, it is seeping again. What better time than the present. Not only that, look at the 11 o-clock position. Yep, the infamous crank sensor. Even though it is not that old, might as well replace it again. 3 MINUTES tops! And while I wait for transmission parts this is a perfect time to tackle that pesky passenger side header gasket leak that has been bugging me.

[

All cleaned up with a new CPS awaiting the cover and seal.


Last edited by pearlpower; 08-01-2011 at 03:53 PM.
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Old 07-31-2011, 06:58 PM
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Awesome stuff there pearl.
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Old 07-31-2011, 07:15 PM
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Great info Pearl. Can you post a pic and part number of your TC?
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Old 07-31-2011, 08:19 PM
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nice write up thank you
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Old 07-31-2011, 11:30 PM
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I've rebuild a few auto trannies before and they really aren't rocket science. I have a question for you though, do you have a manual for this? I have used ATSG manuals before and loved them.
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Old 07-31-2011, 11:50 PM
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Reminded me when I built my V12 tranny last month. She is as strong as an Ox now..
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Old 07-31-2011, 11:53 PM
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Wow impressive. How the heck do you guys know what to do and how to service these things? I don't mind doin things my self but if I don't know how to open the darn thing with out braking it I will never attempt.
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Old 08-01-2011, 12:09 AM
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Originally Posted by malahhaor View Post
Wow impressive. How the heck do you guys know what to do and how to service these things? I don't mind doin things my self but if I don't know how to open the darn thing with out braking it I will never attempt.
Bro I have anxiety looking at those pics. With that said, I have huge respect for you guys who can open her up like this and make her better!
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Old 08-01-2011, 12:12 AM
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Originally Posted by malahhaor View Post
Wow impressive. How the heck do you guys know what to do and how to service these things? I don't mind doin things my self but if I don't know how to open the darn thing with out braking it I will never attempt.
Like anything else, just one step at a time. Stay organized, never race the clock, bit of common sense, and your there. oh, and a crap load of tools. LOL.

Last edited by pearlpower; 08-01-2011 at 12:20 AM.
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Old 08-01-2011, 12:12 AM
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Originally Posted by TheVazha View Post
Bro I have anxiety looking at those pics. With that said, I have huge respect for you guys who can open her up like this and make her better!
Thank you, one of these days, us So Ca AMG owners need to get together.
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Old 08-01-2011, 12:19 AM
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Generic 722.6 trans overview attached for those that would like to see what makes it all go.
Attached Files
File Type: pdf
722.6.pdf (342.6 KB, 5254 views)
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Old 08-01-2011, 12:55 AM
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Originally Posted by pearlpower View Post
Generic 722.6 trans overview attached for those that would like to see what makes it all go.
That actually helps a lot. But is that ALL you used?
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Old 08-01-2011, 01:04 AM
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Originally Posted by TheVazha View Post
Bro I have anxiety looking at those pics. With that said, I have huge respect for you guys who can open her up like this and make her better!
+1 !!!
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Old 08-01-2011, 08:45 AM
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Nice work there brother, do you plan to put in an aftermarket stall while you are at it?
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Old 08-01-2011, 11:19 AM
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Does anyone know if a Gear Vendors unit would work with our transmissions?!

http://www.gearvendors.com/
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Old 08-01-2011, 11:25 AM
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I'm with the guy up top a few. Viewing insides of trannys make me weak in the knees. Like watching those surgery shows when they start getting out the hammers and stuff. Gotta shut her off at that point.

Just so clueless on them but wouldn't think twice about ripping my engine down and popping out a piston.

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Old 08-01-2011, 12:16 PM
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Originally Posted by pearlpower View Post
Like anything else, just one step at a time. Stay organized, never race the clock, bit of common sense, and your there. oh, and a crap load of tools. LOL.
Mad props to you.... don't see this level of DIY repair very often around here.

Looks like a VERY clean and organized shop too; any other shots of the workshop area?


-G
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Old 08-01-2011, 02:11 PM
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Great dedication and Thank you for a wonderful step by step process, with fantastic images.
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Old 08-01-2011, 04:00 PM
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Originally Posted by chawkins2001 View Post
Nice work there brother, do you plan to put in an aftermarket stall while you are at it?

If anything I would prefer a lighter converter vs. a higher stall unit, but have not put much effort into shopping for a converter just yet.

Originally Posted by GT-R View Post
I've rebuild a few auto trannies before and they really aren't rocket science. I have a question for you though, do you have a manual for this? I have used ATSG manuals before and loved them.
Yes, they make great manuals.

Originally Posted by KLR CLS View Post
Great info Pearl. Can you post a pic and part number of your TC?
Sure, be happy to.
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Old 08-01-2011, 11:23 PM
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Is there anything that you could change to make the transmission stronger? I know that renntech offers a transmission upgrade, but I'm not sure what it consists of. I know that the transmissions are pretty stout, but like you said each model has its own specs. I wonder what the slr transmission is like.
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Old 08-05-2011, 04:46 PM
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Interesting as the more people I call, the more they say to go with OEM MERCEDES AMG clutch plates. Even the SRT-8 transmissions are offered the AMG clutch plates as upgrades from their Made in China Chrysler linings.

Talking to a few people , there was a custom batch of heavy duty linings made for this car, but those places want the entire transmission sent to them.

Again, the transmission has held up nicely with the AMG friction so I might just go that route, I would hate to risk putting in something 'similar' to OEM as they put it and shred the material at the first launch.

Also, though the transmission does have single sides plates, the K2 is double sided . Not sure why AMG did that, guess they did not expect people to increase the torque on this car. I may switch these out to single sided-just more of them.

Additionally, as expected since I have been in the auto business for 16 years, most of the customer service has been pretty rough, but then I did not go into this with a high level of expectation so my disappointment with these suppliers is expected. Right now I think I think I will sleep better with genuine AMG clutch packs.


Some random info:

Clutch packs B1,B2,B3,K1,K2,K3

1st gear B2,K1&K3
2nd gear B2,K1,K3
3rd gear B2,K1,K2
4th gear K1,K2,K3
5th gear K2,K3,B1
Rev gear B3,K3,B1

Last edited by pearlpower; 08-06-2011 at 08:38 AM.
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Old 08-05-2011, 05:08 PM
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It all started with a leak ... LOL ... I know how that goes! Thanks a lot for sharing! Might want to check out NAG stuff that several of the Cherokee SRT8 guys run. I am no expert on Auto trannies though ... Let me know if there is a 6 speed manual swap I could do :P ... seriously though .. great stuff!
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Old 08-06-2011, 04:11 AM
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Wow just saw this. Amazing work! Thanks for the pics and write up!

I think my 55 will be needing this soon I can feel the transmission jerking too much and just did the TCM reset with new conductor plate and seal ring connector. Hmmmm
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Old 08-06-2011, 12:22 PM
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Same here, gonna do a TC Upgrade and flush and see how that live, else is time for an SHR or paramount trans upgrade
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