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  #1  
Old 12-28-2007, 08:45 PM
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Location: Toronto, Canada
Posts: 700
Successful 722.4 rebuild

Hi guys

I wanted to share a success story with everyone.

For the past year I've been restoring my 1985 190E 2.3L, I started off with a whole lot of body work and a front end rebuild. The body work was quite extensive, and included welding in new panels to patch up some holes, as well as a partial respray, the reason it was partial is because I was testing some things out, and I decided to renew the driver door which was in the worst shape of all the other body parts, no accidents, just dings, rust, and other road damage.

The suspension rebuild included just about everything new except for shocks. The reason for it was that my spring perch collapsed. I welded it back in, replaced both springs, all the bushings on the control arms, tie rods, ball joints, and any other part that was worn, the list is a long one, and I'm not sure if I remember everything anymore.

You might ask yourself why go so far with a car this old, well, I had the car since April 2002, and it served me very well with very few problems. When I bought it I knew nothing about cars, and everything I know is because of this car. While it was still on the road before all the above mentioned work, I had the engine rebuilt, and it ran beautifully, so getting rid of the car would be a shame really, this is why I continued on with my work.

About 4 months ago, when I finsihed some engine work, I noticed that my transmission was leaking really bad, out of the 7L of fluid that goes into this thing, I would say 3 were on the floor, mind you, the transmission always had a leak here and there, but this was much much bigger. Prior to that I once had a few problems on the road where the car would not shift into a higher gear in slow traffic conditions. When I summed all this up, I came to the conclusion that a rebuild would be in order, especially since I just paid for a tranny rebuild on my 98 Ford Ranger pick up since the reverse band broke.

So, off I went looking for way to get a working transmission into my benz. A rebuild at any of the places I knew would cost minimum $3000. I could not locate a fresh tranny for this car anywhere around here, and a used one is just as good as the one I had. So, I decided to try and rebulid it myself.

I gathered up some literature, studied it in detail to get an idea as to what will yield problems, and if there are any specialty tools I would need. Sure enough, I had to order a special socket for the yolke nut, and a clutch spring compressor. The rest were ordinary run of the mill tools you can pick up at your nearby hardware store.

Finding a rebuild kit was also no easy task, but thanx to Cobra Transmissions, I got more then I needed for a good price as well, these guys knew what this tranny was all about, and even though they lack a decent online order form, over the phone they knew exactly what I needed, and in about a weeks time I had a kit, a new front brake band, and a whole lot of other parts I had no idea I would ever find in a transmission.

The next step was actually getting this transmission out of the car, this was no easy task without a hoist, but, I did it. I used an atv jack to get the transmission down and out, the exhaust and driveshaft had to go before I could even get to it, but I did it.

Finally came the time to actually open this thing up. Not knowing what territory I'm moving into, I cleared a big counter top, got a lot of baggies, labels, twist ties, and boxes to store parts in as I take them out. I followed the MB 722.3/4 manual for the tear down, it didn't take long at all, soon my contertop was filled with parts, and in the process I photographed everything, a real good idea as it turned out.

I started my rebuild with the Valve body since I worked on weekends while I was at home alone studying, since at the same time I was taking some courses, and working full time, and I didn't need an extra pair of hands for the VB. Everything went perfect except when I realized my kit did not come with teflon rings for the VB pistons. I thought, that's okay, I'll get the from the dealer... no luck there either, the dealer refused to help, and I got brushed off, very heart breaking. So I used the old teflon rings, they were not damaged, but they were old, but still in good shape. I put the VB back together piece by piece and moved on to the clutches.

The clutches are real easy, but some tricks must be applied to make them seem that way, and you can't touch them without a press or a clutch spring compressor, which came in a few days prior to this. K1 and K2 looked like new until I got to the orings which were under the piston supports, those crumbled away in my hands as was expected. A kit was actually provided to fix these, but for some reason, it only had 1 oring, and I needed 2. A local seals distributor gave me one for free and I moved on. having the K1, and K2 rebuild, measured and withing spec, I moved onto K3 and the tranny pump.

K3 was completely burnt, I posted some pictures of it earlier if anyone is interested, there was half a layer of lining left out of 6 layers. Burn marks all over the place, and the steels were in terrible shape. The pump itself was not too bad until I opened her up. There is a tiny check valve in the pump which consists of a small plastic piece, and a ball bearing. The plastic crumbled away, and the ball bearing got sucked into the piston causing some minor damage to the contact surface for the seal. That little check valve stalled my work for 3 weeks as I waited for it to come in since it was on back order from the dealer... amazing really, but what can you do?
After 3 weeks, I made sure the pump is in order, repaired the damaged surface, installed the new check valve, and was ready to move on.

Around this time my exams came around, and I had to stop working again for about 2-3 weeks as I prepped for them, I didn't want to screw up my marks just cause of a transmission, so the project went on hold again.
Right after exams which was December 14th, I went back to work. My dad who is a QA guy at a machine shop that makes airplane parts provided me with some measuring tools to check B3 clerance, it sure came in handy, I had an extra set of steels for this guy, and I got it right where I wanted it, and I was ready to put the whole thing back together. Of course, it was not a flawless process, and once or twice I had to crack it open after sealing everything up since a part or two got misplaced, but, it did not bother me that much.

Finally the time came to put the transmission back into the car, taking it out was a lot easier, that's all I can say. My dad helped me out, the engine without the weight of the tranny no longer sat the same, the height and alignment was difficult to get, and again, without a hoist, this was no easy task, but once more, I managed to get the transmission back in place. I should mention that before this, I replaced the rear main seal since I hate leaks

One driveshaft, and exhaust system later, and I have to say I hate working on exhaust on this car especially since I realize I need a new one. 6L of tranny fluid went in, and I sprung a leak, a big one. I thought all my work went down the crapper, but after a few moments, I realized that my car is on ramps, and the fluid is not going to work itself into the torque converter or VB on its own, hence it's probably pouring out the vent valve, the rate at which it leaked kind of made sense too, so I corssed my fingers, put everything back together, took the car off the ramps, put in a fresh oil filter, fresh oil, checked again for leaks, and I was ready to give it a try.

Then I realize the battery is dead, and it needed charging, so I had to wait an hour more, but finally, I cranked the engine, it was a little sleepy at first since the fuel in it is over a year old, and the pump was lazy too, but it started up as if nothing ever happened.

I let the car sit for a while as it warmed up, checked for leaks again. Clouds of smoke started pouring out of the engine bay as the antiseize grease on the exhaust parts burnt up, and any other oil that ended up on the exhaust, eventually it all died out, and slowly I took the tranny through every gear with my foot on the brake.

Since I was in my garage, Reverse was first, I did not feel it engage at all, but... it did, very softly. I took my foot off the brake, and the car started to roll backwars out of my garage and onto the driveway. My driveway is inclined, so the car made it half way up before I had to give it some gas to keep it moving, and... it refused to go. After some looking over, I realize that the little metal lever that connects the fulcrum lever assembly to the throttle was disconnected, again, I fixed it in a split second, gave it some gas and it roared in gratefulness. I hoped back into the car, throw in Reverse, and up the drive way I go onto the road.... quiet as a mouse, not a peep out of the transmission or any other parts, except the brakes, but can you blame them?

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1985 190E 2.3L - a constant project.
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  #2  
Old 12-28-2007, 08:47 PM
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Location: Toronto, Canada
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Now it was time for the forward gears, slowly into Drive and a little bit of gas.... it moves, down the street, second to third was a bit delayed, but I can understand that, two three more shifts and it was exactly where it should have been. I didn't get enough speed to get it into the fourth gear, that will take place later on, but it flowed down the road like a brand new car.

I turned it around, some things fell of the roof since I forgot I put a whole bunch of junk up there, had to stop and pick it up, and back home I went. Checked the fluid level, it needed to be topped off, and back into the garage, so I can put the grill and fender back on.

All in all, I'm amazed it works, and I never opened up a transmission before, all I did was use common sense, and followed the book. I hope to have it back on the road when it stops snowing and the salt is gone, and when the body wears away, I'll have to find a donor body for the engine and tranny.

Final cost, about $1000, so that's $2000 towards a 300E

A Christmas Miracle

Cheers everyone

xp
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  #3  
Old 12-28-2007, 10:52 PM
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Join Date: Apr 2005
Location: Northern Louisiana
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Great job, I enjoyed reading this, thanks! and Happy Motoring!
RR
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  #4  
Old 12-28-2007, 11:33 PM
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Location: Decatur, Illinois, USA
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Good job! WOndering...you done with the 722.4 tranny rebuild manual? I would like to borrow it or buy it, would pay for the shipping cost to borrow... I need to learn about my 722.410 tranny for a rebuild.
Crhenkel@aol.com
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1990 190E 2.6 - Arctic white SOLD
1986 190E-16v - Blauswartze
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  #5  
Old 01-02-2008, 12:23 PM
smitty5
 
Join Date: Jul 2007
Location: SW Ohio
Posts: 2
Good job! I need a manual (or copy) for the 722.4 tranny also. Got any ideas where one can be had? Thanx.
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  #6  
Old 01-02-2008, 05:43 PM
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Makes me feel good to read a story like that.

Good Job!
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  #7  
Old 01-02-2008, 06:06 PM
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Fantastic job.

It's really a pleasure to see someone fearlessly tear into a M/B automatic and be successful in its complete overhaul.

Congrats.
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  #8  
Old 01-02-2008, 06:16 PM
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i am impressed.... just the fact that you got it out and back in...

i would draw the line there....

Congratulations!
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1989 300ce 129k
( facelifted front,updated tail lights, lowered suspension,bilstein sports, lorinser front spoiler, MOMO steering wheel, remus exhaust,stainless steel brake lines). (Gone)

1997 s320 154k (what a ride). Sold with 179k miles. Replaced with Hyundai Equus

1994 e320 Cabriolet 108k



1972 280se 4.5 153k Owned for 12 yrs, sorry I sold it


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  #9  
Old 01-02-2008, 06:58 PM
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Good job.
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  #10  
Old 01-02-2008, 09:18 PM
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Nice work xp190.
That's called determination.
Speaking of which,...did you ever find another girlfriend or are you still dating your cousin ?
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  #11  
Old 01-02-2008, 10:00 PM
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Location: Ashland, MA
Posts: 2,602
Wow

Nice job. I just had my truck transmission rebuilt. I stopped by the shop when they had it apart. There was a bin with my transmission in it. The only thing I recognized was the valve body. It looked like there was a hundred pieces in the bin. You even rebuilt the valve body, amazing.

Big surprise the dealer wouldn't help you. It was nice of the local sales distributor to give you the part you needed.

Can you let us in on the cousin joke?

Chris
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Old 01-02-2008, 10:47 PM
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Location: Toronto, Canada
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I'm surprised manny still remembers

been seeing some other girls since then, but nothing special yet.

For those of you interested in the manual, I actually found one through our forum, here is one link where you can order one manual, you can thank Deanyel for this one, you have to order this one, the next few are free.

http://www.atsg.biz/cgi-bin/shopper.cgi?search=action&category=EIMP&keywords=all&pricecode=&passsubnum=

This manual, although it came in real handy was missing a few things with regards to my transmission. I found that there are many variations between every transmission, in some you will find a spring in one place, but not in the other, so the best thing to do is write your own manual as you go along, I did this by taking lots of pictures, which I will post a few of for everyone to see.

Another manual can be found here, S-Class Guru pointed me to this one

http://w126.pp.ru/akp722.pdf

I actually have not used this one at all, but it's good reference material

Myamar pointed me to this one, so far it's the best, but, the pictures are for the 722.3 transmission, however, all else works just fine for the 722.4 as well, many thanx myamar, this was a life saver.

http://www.w124performance.com/docs/mb/other/tranny_722_repair.pdf

The ASTG manual was very good for the valve body, and the repair of the hidden orings in the clutch packs, I'm not sure if you can actually find that fix anywhere else, so if anyone is interested, please let me know and I will scan the pages and post them up.

These manuals, a whole lot of parts, and a lot of patience as well as help from this forum is what got me through the project, I have to say that for a transmission this old, it is a very solid piece of machiner. It's inner workings are unbelivably complex, especially if you see the 4 layer valve body, whoever designed it and brought it from a blue print to reality must have been really really smart.

I'll finish this post and in the next one add some pictures for everyone to look at, describing what's inside one of these marvels will take too long

xp
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Old 01-02-2008, 10:50 PM
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Well done XP! You are an inspiration to us all.

Especially to me. My wife's 190e has just lost reverse, mostly. The posts suggest that it is the seals around the reverse piston, so what the heck, I am going to look inside. The car is not worth a lot with a dud transmission. Worst case scenario, I get one from a wrecker and cross my fingers that it is OK. But why give up without a fight?

So I have ordered the gaskets/seals/clutch plates kit, and I am saving clear plastic egg cartons and cardboard boxes. I hope the dealer will not be as awkward as yours, as the local dealers are all operated by MB Canada.

My local parts guy thinks that I will find nothing rebuildable inside, but I am not so sure. It ran well, until the discrete problem of reverse goiing out. It still runs well in the forward gears. We shall see. The car has 360,000 km (225,000 miles), and I think that the transmission is original.

Thanks for your post. It is encouraging.

Andrew
1989 190E 2.6
1994 Jaguar XJS 4.0
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  #14  
Old 01-02-2008, 10:59 PM
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Alright, now for some pictures, I don't know how this post will turn out but bare with me.

Okay max of 5 files, so lets do 5 per post.

First, the transmission right after it came out of the car, 22 years of dirt, oil leaks, road salt, you name it, this one has seen it.

Successful 722.4 rebuild-picture-1583.jpg
Successful 722.4 rebuild-picture-1584.jpg
Successful 722.4 rebuild-picture-1585.jpg
Successful 722.4 rebuild-picture-1586.jpg
Successful 722.4 rebuild-picture-1587.jpg

You can see in the background the conditions I was working in, not the most plesant, and a huge mess. After I was finished I had to use my truck to pull the benz out of my garage to clean all this up.

It took about 3-5 hours to get the transmission out, and I had to get the utility jack for about $100, so far not too bad...
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Old 01-02-2008, 11:15 PM
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Successful 722.4 rebuild-picture-1600.jpgajme, looking through my manual, no reverse indicates that either the B3 clutch is worn out and the servo does not engage it anymore, the B3 seal is leaking, there are actually 2, the big teflon ring around the pistion itself which is most likely fine, or the rubber guide seal, that might be your problem right there. If the reverse went out slowly, then it's your band that is slipping and you will have to replace it, or get a bigger pin, but replacement is probably a better option. In order to replace the seal, everything must come out, if you look through the manual, the B3 seal, is the very first thing you install on an empty bell housing. Lastly, the pump clerance might be too big, but since forward gears work, that is probably fine.


Now for some more pictures

In this series of 5 you can see the first tear down steps, first the rear cover comes off, in order to take it off you need a special socket for the yolke nut, and the nut itself must be replaced.
Successful 722.4 rebuild-picture-1591.jpg
Successful 722.4 rebuild-picture-1594.jpg
Successful 722.4 rebuild-picture-1595.jpg

The rear cover has quite a few parts behind it, the speed cable comes in through it, the governor which is transmission specific, so if you ever take it out, make sure you don't break it, and put it back in to the same transmission, these are not interchangable. You can also see the parking ratchet, if you ever wonder what makes that click when you put your car into park and it rolls a bit, then clicks and stops, that big dirty lever does it when it clicks into the sprocket on the output shaft.

Finally, you can see what's behind all the pretty parts hiding behind the rear cover... nothing really, the output shaft goes into a seperate compartment, so you are done with this part

And now the governor itself, the cover is real easy to take off, no pressure on it what so ever, just don't break it

Successful 722.4 rebuild-picture-1601.jpg

With the governor and all the parts behind the rear cover out, you can take the entire planet assembly out, but it will have some challanges, so it's better to do what the manual says.

xp

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