99 W163 Transmision Project - PeachParts Mercedes-Benz Forum

93w124 · #1 12-28-2010, 08:59 PM

I inherited a 1999 ML320 with 130K miles last week with a transmission problem I hope to fix with DIY elbow grease in the next few weeks. The gearbox was never serviced since the vehicle was purchased. The 13-pin electronics connector on the gearbox is soaked with ATF and needs R+R. Shifting symptoms include locking up in 1st gear during harsh acceleration, sometimes slips to neutral from 4th gear when forced to climb uphill, and will not downshift to 3rd or 2nd from 4th when needed. Very unreliable improper shifting. Spent some time looking into some common 722.6 gearbox issues out there and found it may be one of these suspects:

1. R+R ATF and Filter (Gearbox Service and Correct ATF Level)
2. 13 pin electronics connector causing faulty signals to ETC due to ATF leak.
3. Possible damage with conductor plate/electronics kit in transmission.
4. Damaged Pressure Regulator Spring in Valve body.
5. Damaged ETC Module

I plan to DIY 1,2,3, and 4 with some online reference materials then have the fault codes erased to see if they make a difference. Took it to a local dealer to get the fault codes ($160.00 ouch!). Please share your thoughts. I appreciate any input. Thanks!

ETC- Electronic Transmission Control PIN 11
--------------------------------------------
52 The torque converter lock-up clutch causes impermissable closing.
65 Component N 15/3 (ETC [EGS] control unit) is faulty.
135 CAN Communication with the engine system is sporadically disturbed.
136 CAN Communication control unit instrument cluster is sporadically disturbed.
137 There is a sporadic fault in CAN communication with control module N78 (transfer case control module)
or the transfer case position is sporadically implausible.
146 The Transmission has sporadically an impermissable transmission ratio.
147 The gear is sporadically implausible or the transmission slips sporadically
148 The torque converter lock-up clutch causes a sporadic impermissible closing.

ME2-SFI - Motor Electronics 2 PIN 7
------------------------------------
P0700-105 Read out fault memory of control unit ETC
P0300-080 Misfiring Damages TWC
P0306-084 Misfiring of Cylinder 6 Damages TWC

ESP - Electronic Stability Program PIN 9
------------------------------------------
C1012 Terminal 87 Overvoltage
C1022 Fault in CAN communication with control unit N3/10 (ME-SFI [ME] control unit).
C1032 Fault in CAN communication with control unit instrument cluster.
C1140-007 N49 (Steering angle sensor)
C1140-008 Component N49 (Steering angle sensor) is not initialized.
C1120 N64 (ESP yaw rate sensor)

BAS - Brake Assist PIN 9
-------------------------
C1012 Voltage supply circuit 87 : Overvoltage
C1202 A7/7s1 (BAS release swtich) : Plausibility

AAM - All Activity Module PIN 12
---------------------------------
B1703-004 Transponder: error when writing programmable code.
B1858-002 Two-way radio signal: The programmed code is o.k. but the programmable code is not synchronized.
B1786-002 The CL signal contact Tailgate supplies implausible values. - FAULT during locking.
B1040-001 CAN bus: fault in communication: ETS
B1040-003 CAN bus: fault in communication: VG

mbdoc · #2 12-29-2010, 08:33 AM

Since you are going after a trans issue...

Several codes in the trans system are noteworthy due to $$$ cost.

The code 65 is saying that the trans computer is BAD!
Check that computer for fluid migration thru the wiring harness, above the gas pedal area.
The codes 146/147/148 are intermittent codes suggesting that the trans is slipping.
The trans could be low on fluid, filter plugged, OR just worn out clutches.

Good luck, many GOOD independent MB shops in this area would charge less.
What part of town?

93w124 · #3 12-29-2010, 07:07 PM

Thanks for the input MBDoc. I'm in the Snellville/Lawrenceville boundery. Need the codes erased after my DIY project is completed so can you recommend a local MB shop around my area?

I checked the ETC module unit, cables, and 2 connectors inside the car like you suggested for fluid migration and they looked and felt "squeaky clean". No signs of greasy fluids there. Any other procedure that might help confirm if I should R+R the ETC unit or does code 65 mandate a replacement? I plan to service the gearbox one way or the other because its probably overdue, so I figured while I'm at it, might as well replace the E-plug bushings to address the leak and replace the pressure regulator spring as well. I'm still not sure about sinking the extra $$$ for the conductor plate if its not faulty. No "faulty speed/rpm sensor" codes returned above so I'm not sure if I should include the conductor plate R+R during my gearbox service. I'm still kinda pondering that...any thoughts?

mbdoc · #4 12-30-2010, 08:16 AM

Rollins automotive OR Black Forest.

Both have the background to help get you thru that problem.

Do you live near Moon Place road?

93w124 · #5 12-30-2010, 07:11 PM

Yes, I'm close to moon place road. I'm by sugarloaf and 124. Anyone in that area you can recommend?

DieselPaul · #6 12-30-2010, 11:43 PM

Just want to throw it out there, can you pick up a used warrantied gearbox for less than the cost of all those repair parts / the value of your time?

mbdoc · #7 12-31-2010, 10:06 AM

Star tech in Norcross, Bob Dula

93w124 · #8 01-13-2011, 08:44 PM

R/R my conductor plate, e-plug (13-pin connector ATF leak), and found my ATF crept up to the ETC module/connectors. I cleaned both ends of the wire harness w/ electrical cleaner then cleared the ECU and ETC fault codes. Transmission was still shifting funny so I performed the ETC test procedure here:

http://www.benzworld.org/forums/w163-m-class/1416106-code-p0748.htm

(w/out a battery charger hooked up to my battery) and came up with these results:

Test 1) 30/29=10.35V
Test 2) 30/1=0V (Diagnosis Output) (Wiring or N15/3)
Test 3) 30/38=9.67V

Looks like my ETC may be Kaput like Doc suggested. Seeing about getting a re-manufactured unit that can be encoded to my VIN right now...and will report back.

93w124 · #9 02-20-2011, 03:55 PM

Transmission DIY Work Done to Date:

01/05/11 131,287 R+R Conductor Plate
01/05/11 131,287 R+R Pressure Regulator Valve Spring in Valve Body
01/05/11 131,287 R+R w/Upgraded 13-pin Connector Plug at Transmission to fix ATF Leak
01/05/11 131,287 Cleaned Transmission-to-ETC Wiring Loom and both Electrical Connectors w/Electrical Cleaner
01/05/11 131,287 R+R Trans Filter, Pan Gasket, ATF w/ Mobil 1, corrected ATF Level
01/05/11 131,287 R+R Transfer Case Fluid w/Dex3 ATF
01/05/11 131,287 Cleared ME & ETC Fault Codes; Reset ETC Adaptations & Re-Learned
01/05/11: 131,287 ***STILL Transmission Slips @2-3-4?, Shudders@3rd,4th, Limp Mode 2nd, 4th...***
--------------------------------------------------------------------------
01/08/11 131,350 R+R Transmission Shifter Linkage Bushings (Loose Shifter)
--------------------------------------------------------------------------
01/15/11 131,375 Tested ETC: Pin 1 Diagnosis Output NO (0) VOLTAGE! & Pin 17 PWM Solenoid =4.5 ohms???
***ETC or Range Recognition Switch or PWM Solenoid???***
--------------------------------------------------------------------------
01/25/11 131,409 R+R ETC (Siemens 5WK33967) w/MB Dealer Unit PN MB #026-545-86-32-89
01/25/11 131,409 Cleared ME & ETC Fault Codes; Reset ETC Adaptations & Re-Learned
01/25/11: 131,409 ***STILL Transmission Slips @2-3-4?, Shudders@3rd,4th, Limp Mode 2nd, 4th...***
--------------------------------------------------------------------------
02/10/11 131,700 R+R Gear Selector Range Recognition Switch w/ "NEW" switch only (not whole assembly)
02/10/11 131,700 Cleared ME & ETC Fault Codes; Reset ETC Adaptations & Re-Learned
02/10/11: 131,700 ***SHIFTING GOT WORSE! STILL Transmission Slips @2-3-4?, Shudders@3rd,4th, Limp Mode
02/11/11 131,745 Returned ORIGINAL Gear Selector Range Recognition Switch
02/10/11: 131,700 ***STILL Transmission Slips @2-3-4?, Shudders@3rd,4th, Limp Mode 2nd, 4th...***
--------------------------------------------------------------------------
02/11/11: 131,730 Dealer DAS Fault Codes & HHT Adaptation Settings Data Diagnosis K3 Clutch Failure
ME
P0700-105 Read out fault memory of control unit ETC
ETC
52 The torque converter lock-up clutch causes impermissible closing.
146 The Transmission has sporadically an impermissible transmission ratio.
147 The gear is sporadically implausible or the transmission slips sporadically
148 The torque converter lock-up clutch causes a sporadic impermissible closing
--------------------------------------------------------------------------

ETC Adaptation Data Report
***per MB Dealer - K2 Clutch Failure!!!***
--------------------------------------------------------------------------
01 Accel. 1-2 (Nm)
-12 0
-45 -6
3 0

02 Accel. 2-3 (Nm) **Slipping K2 Applied** K2 Clutch Failure Here! per MB Dealer**
120 18
180 96
102 0
** K2 Clutch Failure Here! Per MB Dealer**

03 Accel. 3-4 (Nm)
78 24
90 24
-15 -6

04 Accel. 4-5 (Nm)
-36 0
-102 -24
0 0

05 Decel. 1-2 (Nm)
0 0

06 Decel. 2-3 (Nm)
0 0

07 Decel. 3-4 (Nm)
0 0

08 Decel. 4-5 (Nm)
0 0

09 Accel. 2-1 (Nm)
-30 0
0 0

10 Accel. 3-2 (Nm)
-30 0
0 0

11 Accel. 4-3 (Nm)
-33 0
0 0

12 Accel. 5-4 (Nm)
-33 0
0 0

13 Decel. 2-1 (Nm)
0 0
0 0

14 Decel. 3-2 (Nm)
27 0
-6 0

15 Decel. 4-3 (Nm)
0 0
-27 -12

16 Decel. 4-3 (Nm)
0 0
0 0

17 Fill pressure 1-2 -500 mbar
18 Fill pressure 2-3 -20 mbar
19 Fill time K1 in 2nd Gr = 1 Cycle
20 Fill time K2 = 1 Cycle
21 Fill time K3 = 0 Cycle
22 Fill time B1 = -2 Cycle
23 Fill time B2 = 3 Cycle
24 Fill time K1 in 4th Gr = 2 Cycle
--------------------------------------------------------------------------
One More Try for the heck of it!

02/18/11 131,849 R+R Y3/6y6 TCC Lock-up PWM Solenoid in Transmission Valve Body
02/18/11 131,849 Checked Transmission Valve Body Torque Converter Control Valve for blockages
02/18/11 131,849 Checked Transmission Valve Body 2-3 Command Valve for blockages
02/18/11 131,849 Corrected ATF Level
02/18/11 131,849 Cleared ME & ETC Fault Codes; Reset ETC Adaptations & Re-Learned

02/18/11: 131,849 Miles ***STILL Transmission Slips @2-3-4?, Shudders@3rd,4th, Limp Mode 2nd, 4th...***

--------------------------------------------------------------------------
Current ETC DTC a/o 2/20/2011
52 The torque converter lock-up clutch causes impermissible closing.
148 The torque converter lock-up clutch causes a sporadic impermissible closing
--------------------------------------------------------------------------
Is the K2 clutch shot per adaptation data?..time to replace or rebuild? Any feedback is fully appreciated. Thanks.

mbdoc · #10 02-21-2011, 11:00 AM

The reading of 180Nm on any of the clutch pack adaption is DEATH.

Means that the solenoid is activated for maximum time & that the trans is still slipping.

Overhaul of the trans is required.

93w124 · #11 02-22-2011, 10:55 AM

Thanks Doc. I'll check my options to re-build the trans. I appreciate your advice.