Name _______________________

Skill Module Number:

1.1

Subject: 722.9 Transmission D & A

Objective:
At the conclusion of this module, you will be able to:

Explain how to disassemble the 722.9 transmission

Explain how to assemble the 722.9 transmission

Describe and perform all measurements and adjustments

Identify the components of the transmission

Explain what components can be disassembled and which components

must not be disassembled

Explain which bolts need to be replaced whenever they are removed

Vehicle and tools required:

722.9
Hand tools at workbench
WIS
Beam box

Required material:

Clipboard & pen

Instructions:
1. Follow the instructions and answer the q uestions.
2. Ask your instructor for assistance as needed.

286 Mod 1.1 722.9 Trans D&A (Todd,D) 05-05-04.doc

Mount Transmission and Identify

WIS documents used in this section:

AR27.10-P-0600-01W (Fastening transmission on assembly stand)

1. Mount your transmission on the assembly stand (if not already done.)

2. Does the 722.9 use the same mounting adapter (support plate 140 589 34 63 00) as the
722.6 transmission?

YES

NO

3. Where on the transmission are the identification numbers found?

_____________________________________________________________________

4. Open WIS. In the Unit number: box (lower right), type in 722.9 and select enter.
How many versions of the 722.9 transmission are currently available in the U.S.?
__________________

5. Is there anything incorrect about the sales designation (W6A 700) given in WIS?
_____________________________________________________________________

6. How many U.S. models currently use the 722.9 trans, according to WIS? ___________
Notes:
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________

Instructor check point _______________ Review of section.

286 Mod 1.1 722.9 Trans D&A (Todd,D) 05-05-04.doc

Oil Pan, Oil Filter, Electrohydraulic Control Module , Torque Converter Housing,
Transmission Housing

WIS documents used in this section:

AR27.50-P-0601W

(Detaching, attaching transmission housing to torque converter

housing)
AR27.10-P-7030W
(R&I oil pan and filter)
AR27.19-P-0200W
(R&I electrohydraulic control module)
AR27.50-P-0601-01A (Remove grooved ball bearing in rear of transmission housing)
The instructor will perform the following steps with you as a group using WIS.
During these steps the instructor will provide you with the answers to certain
questions. When the steps for this section have been completed and any questions
you may have are answered, return to your transmission and perform the same
steps. There may be additional questions for you to answer as you complete the
work yourself.

1. Instructor will demonstrate the drift used to remove the fluid level pipe in the oil pan.
2. Remove the oil pan, the filter and the ElectroHydraulic Control Module (EHCM). Also,
remove the plastic supply pipe & note installation orientation.
3. Instructor to point out the filter screen that is in the oil return circuit from the torque
converter. If this screen had metal debris caught in it, what component would you
suspect? _____________________________________________________________

4. Put the EHCM, the filter and the other parts in the oil pan and put them aside in a safe
place. Well take a closer look at them later.

5. Remove the output flange, rear seal, bearing, and the shim under the bearing.

6. Why would you need to use the two legged puller to remove the output flange?
___________________________________________________________________
___________________________________________________________________

286 Mod 1.1 722.9 Trans D&A (Todd,D) 05-05-04.doc

7. Would the rear bearing removal tool work correctly if the bearing was put in the other
way round?

YES

NO

8. Instructor will demonstrate the removal tool for the transmission housing.
9. Remove the transmission housing from the torque converter housing.
Return to your transmission and complete the steps just demonstrated to you.
Answer any additional questions:
8. What bolts would need to be replaced (if any) upon reassembling the transmission from
the above steps?
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________

Notes: __________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________

Instructor check point _______________ Review of section.

286 Mod 1.1 722.9 Trans D&A (Todd,D) 05-05-04.doc

Brakes B2 & BR (BPC), Park Pawl

WIS documents used in this section:

AR27.50-P-0610W
AR27.50-P-0782W
AR27.50-P-0880W
AR27.50-P-0880-01W
AR27.51-P-7229W
AR27.51-P-7229-01W

(R / install main components of the transmission)

(Remove / install BPC clutch pack)
(Dismantling / assembling multi-disc brake B2)
(Assembling piston guide & external plate carrier of B2)
(Measure & adjust clearance)
(Measure & adjust clearance of BR multi-disc brake)

Instructor will demonstrate / discuss the following steps:

1. Remove the BR (BPC) clutch pack and disc spring.
2. Remove brake B2 and the park pawl gear.
3. What material are the B2 piston guide retaining bolts?

Steel

Aluminum

4. What is the part # of the special tool used to disassemble B2 piston?

__________________
5. Disassemble, assemble, and measure B2.
6. When reassembling piston guide & external plate carrier, where should the opening in
external plate carrier face?

Upwards

Downwards

7. Install the park pawl gear and B2 into the case.

(Note: All bolts on school transmissions should only be finger tight.)
8. Install and measure BR (BPC).
9. Place transmission housing aside, out of the way.
Return to your transmission and complete the steps just demonstrated to you.
Answer any additional questions:
B2

BR

10. How many discs do B2 & B R have?

____________

____________

11. What are the specified clearances for B2 & BR?

____________

____________

12. What are the actual clearances of B2 & BR?

____________

____________

286 Mod 1.1 722.9 Trans D&A (Todd,D) 05-05-04.doc

13. What is the tightening torque of the B2 piston guide bolts?

________________

14. What pressure force marking is used to measure B2?

________________

15. What pressure force marking is used to measure BR?

________________

Notes: __________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________

Instructor check point _______________ Review of section.

286 Mod 1.1 722.9 Trans D&A (Todd,D) 05-05-04.doc

Remove Output Unit and Disassemble / Assemble All Components: K3, Rear Hollow
Shaft, Rear Planet Carrier, Output Shaft and Rear Internally -geared Wheel.

WIS documents used in this section:

AR27.50-P-0611W

(K3, removing / installing rear hollow shaft, rear planet

carrier and output shaft)
AR27.51-P-0830W
(Disassemble / assemble clutch K3)
AR27.50-P-0851W
(Dismantle / assemble rear tubular shaft)
AR27.50-P-0810-01A (Checking / adjusting end play between shim & circlip)
Instructor will demonstrate / discuss the following steps:
1. Remove the output unit by grasping the output shaft and lifting upwards.
2. Remove Torlon rings from output shaft.
3. Remove K3.
4. What special tool is used to D & A K3?

_______________________________

5. Disassemble, assemble, and measure K3. Set aside.

6. Remove, disassemble and reassemble rear hollow shaft.
7. Which sun gears can be seen at this point on the hollow shaft?
________________________________

_______________________________

8. How many seals are on the output shaft?

________

9. Reassemble output unit.

10. Check axial end play.

286 Mod 1.1 722.9 Trans D&A (Todd,D) 05-05-04.doc

Return to your transmission and complete the steps just demonstrated to you.
Answer any additional questions:

9. When installing the single-sided friction discs, which way should the friction side face?
Up

Down

10. How many internally toothed single -sided friction discs does K3 have?
____________
11. What is the specified clearance for K3?

_______________________

12. What is the actual clearance of K3?

_______________________

13. What pressure force marking is used to measure K3?

_______________________

14. What is the specified clearance of axial end play at K3?

_______________________

15. What is the actual clearance of axial end play at K3?

_______________________

Notes: __________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________

Instructor check point _______________ Review of section.

286 Mod 1.1 722.9 Trans D&A (Todd,D) 05-05-04.doc

Remove Drive Unit: Rear Ring Gear, Drive Shaft w/ K2, Front Planet Carrier

WIS documents used in this section:

AR27.50-P-0612W (Removing / installing drive shaft w/ K2, front planet carrier,
internal plate carrier w/ K1 & B3)
AR27.51-P-0820W (Dismantling / assembling clutch K2)
Instructor will demonstrate / discuss the following steps:
Note: use caution, as the front planet gear carrier has very sharp edges!
1. Remove the drive shaft / K2 / front planet gear carrier assembly by grasping the ring
gear and lifting straight up. Place the drive shaft in the hole in the work bench (if
provided.)
2. Remove the rear ring gear.
3. Now lift the K2 / drive shaft assembly out of the front planet gear carrier.
4. Instructor will point out the speed sensor exciter rings.
5. Set the planet gear carrier aside.
6. Disassemble, reassemble, and measure K2.
7. Reassemble the complete drive unit except for the rear ring gear. Set drive unit and ring
gear aside.
Return to your transmission and complete the steps just demonstrated to you.
Answer any additional questions:

8. How many internal toothed single-side discs does K2 have?

____________
9. What is the specified clearance of K2?

_______________________

10. What is the actual clearance of K2?

_______________________

11. What pressure force marking is used to measure K2?

_______________________

Instructor check point _______________ Review of section.

286 Mod 1.1 722.9 Trans D&A (Todd,D) 05-05-04.doc

Internal Plate Carrier w/ K1 & B3

WIS documents used in this section:

AR27.50-P-0890W (Dismantling / assembling multi-disc brake B3)
AR27.51-P-0800W (Dismantling / assembling clutch K1)
Instructor will demonstrate / discuss the following steps:
1. Remove multi-disk brake B3 along with internal plate carrier from B1 assembly.
2. Remove the internal plate carrier from B3 and set aside.
3. Disassemble B3 completely.
4. What is unique about the seal of B3?
_____________________________________________________________________
5. Reassemble the piston, piston cover and return spring assembly.
6. Reassemble the rest of the clutch parts and measure B3 clearance. Set B3 aside.
7. Lift out multi-disk K1 assembly.
8. Disassemble K1 completely. Note the return spring assembly. (Dont pull it apart.)
9. What is unique about the seal of K1?
_____________________________________________________________________
10. Reassemble K1 assembly and measure clearance. Set K1 aside

Return to your transmission and complete the steps just demonstrated to you.
Answer any additional questions:

11. How many internal toothed single-sided discs does B3 have?

___________

12. What is the specified clearance for B3?

_______________________

13. What is the actual clearance of B3?

_______________________

14. What pressure force marking is used to measure B3?

_______________________

15. What special tool is used to disassemble B3?

_______________________

286 Mod 1.1 722.9 Trans D&A (Todd,D) 05-05-04.doc

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16. How many internal toothed single-sided discs does K1 have?

___________

17. What is the specified clearance for K1?

_______________________

18. What is the actual clearance of K1?

_______________________

19. What pressure force marking is used to measure K1?

_______________________

20. What special tool is used to disassemble K1?

_______________________

Instructor check point _______________ Review of section.

Notes: __________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________

286 Mod 1.1 722.9 Trans D&A (Todd,D) 05-05-04.doc

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Remove Multi-disk Brake B1 and Oil Pump

WIS documents used in this section:

AR27.50-P-0721W (Remove / install multi-disk brake B1 and oil pump)
AR27.50-P-0870W (Dismantling / assembling multi-disk brake B1)
Instructor will demonstrate / discuss the following steps:
1. Unbolt oil pump and remove it from the torque converter housing.
2. What is different about the oil pump, compared to a 722.6 pump?
_____________________________________________________________________
3. Unbolt multi-disc brake B1 and remove it from the torque converter housing.
4. Disassemble B1, and then reassemble and measure its clearance.
Return to your transmission and complete the steps just demonstrated to you.
Answer any additional questions:

5. How many internal toothed single-sided discs does B1 have?

___________

6. What is the specified clearance for B1?

_______________________

7. What is the actual clearance of B1?

_______________________

8. What pressure force marking is used to measure B1?

_______________________

9. What special tool is used to disassemble B1?

_______________________

10. What is the tightening torque of the oil pump bolts?

_______________________

11. What is the tightening torque of B1 bolts?

_______________________

Instructor check point _______________ Review of section.

Notes: __________________________________________________________________
________________________________________________________________________
________________________________________________________________________

286 Mod 1.1 722.9 Trans D&A (Todd,D) 05-05-04.doc

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Reassembly and Measurement of End Plays

WIS documents used in this section:
AR27.50-P-0600-06A (Measure axial play between park pawl gear and grooved
ball bearing)
AR27.50-P-0600-05A (Install grooved ball bearing in rear transmission housing check play)
Instructor will demonstrate / discuss the following steps:
1. Assemble in reverse order.
2. Measure a xial end play after installing transmission housing (before installing bearing.)
3. Check play after installing rear bearing and circlip.
4. Install rear seal & flange.
5. Should the flange collar nut be reused?

YES

6. What is the tightening torque for the collar nut?

NO

____________

7. What other installation note is there regarding the collar nut?

_____________________________________________________________________
Return to your transmission and complete the steps just demonstrated to you.
Answer any additional questions:

8. What is the tightening torque of the transmission housing bolts?

____________

9. Should the old bolts be reused?

YES

NO

10. What is the specified axial end play between park pawl and grooved ball bearing?
_______________________
11. What is the actual axial end play between park pawl and grooved ball bearing?
_______________________
12. What is the specified end play between grooved ball bearing and circlip?
_______________________
13. What is the actual end play between grooved ball bearing and circlip?

____________

Instructor check point _______________ Review of section.

286 Mod 1.1 722.9 Trans D&A (Todd,D) 05-05-04.doc

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Electrohydraulic Control Module, Oil Filter, Oil Pan

WIS documents used in this section:

AR27.19-P-0200W
(Remove / install electrohydraulic control module)
AR27.19-P-0200-01A (Insert selector valve into driver of detent plate)
AR27.00-P-0270W
(Fill automatic transmission with oil)
Now perform the following steps:

1. Does your transmission have the modified oil pan or the original style?
Modified

Original

How do you identify the original vs. the modified pan? ___________________________
______________________________________________________________________

2. Look at the electrohydraulic control module (valve body with control module, solenoids,
etc.) Does it appear that it could be disassembled?
Should you ever disassemble it?

YES

NO

YES

NO

Why or why not? ____________________________________________________

3. Match the following items with the callouts in the picture on the following page:
Hint: GF27.19-P-5104-01N (Electric control unit, design)

electric control unit _______________

selection range sensor ________________

floats __________________________

integrated trans control unit ____________

turbine speed sensor ______________

output speed sensor _________________

internal speed sensor ______________

trans oil temp sensor _________________

brake B1 solenoid valve ____________

clutch K1 solenoid valve ______________

brake B2 solenoid valve ____________

clutch K2 solenoid valve ______________

brake B3 solenoid valve ____________

clutch K3 solenoid valve ______________

working pressure solenoid valve _______________________

torque converter lockup clutch solenoid valve _____________

286 Mod 1.1 722.9 Trans D&A (Todd,D) 05-05-04.doc

14

4. Reinstall the electrohydraulic control module, filter and pan. Dont forget the plastic
supply pipe.

286 Mod 1.1 722.9 Trans D&A (Todd,D) 05-05-04.doc

15

5. Can you reuse the valve body to transmission housing bolts?

6. What is the tightening torque of the valve body bolts?
7. Can you reuse the oil pan bolts?
8. What is the tightening torque of the oil pan bolts?

YES

NO

__________________
YES

NO

__________________

Instructor check point _______________ Review of section.

Notes: __________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________

286 Mod 1.1 722.9 Trans D&A (Todd,D) 05-05-04.doc

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