2006 MERCEDES-BENZ SPRINTER automatic transmission

NOTE: The sleeves and pistons of the overlap reg-
ulating valves must not be mixed up.
(2) Install all valves and springs from the valve
body (1) (Fig. 136). Check all valves for ease of move-
ment and shavings.
(3) Install the screws to hold the side covers to the
valve body. Tighten the screws to 4 N´m (35 in.lbs.).
Fig. 136 Valve Body Components
1 - VALVE BODY 8 - SHIFT VALVE PRESSURE REGULATING VALVE
2 - 1-2/4-5 COMMAND VALVE 9 - B2 SHIFT VALVE
3 - 1-2/4-5 HOLDING PRESSURE SHIFT VALVE 10 - 2-3 HOLDING PRESSURE SHIFT VALVE
4 - 1-2/4-5 SHIFT PRESSURE SHIFT VALVE 11 - 2-3 COMMAND VALVE
5 - 1-2/4-5 OVERLAP REGULATING VALVE, SLEEVE, AND PIS-
TON12 - 2-3 SHIFT PRESSURE SHIFT VALVE
6 - SHIFT PRESSURE REGULATING VALVE 13 - TCC LOCK-UP REGULATING VALVE
7 - REGULATING VALVE PRESSURE REGULATING VALVE 14 - TCC DAMPER VALVE - if equipped
21 - 126 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATIONVA

(4) Install all valves and springs into the valve
housing (2) (Fig. 137). Check all valves for ease of
movement and shavings.
(5) Install the screws to hold the side covers to the
valve housing. Tighten the screws to 4 N´m (35
in.lbs.).
NOTE: A total of 12 valve balls are located in the
valve body, four made from plastic (4) and eight
from steel (1, 3).
Fig. 137 Valve Housing Components
1 - 2-3 OVERLAP REGULATING VALVE, SLEEVE, AND PISTON 6 - 3-4 SHIFT PRESSURE SHIFT VALVE
2 - VALVE HOUSING 7 - 3-4 OVERLAP REGULATING VALVE, SLEEVE, AND PISTON
3 - SELECTOR VALVE 8 - OPERATING PRESSURE REGULATING VALVE
4 - 3-4 HOLDING PRESSURE SHIFT VALVE 9 - LUBRICATING PRESSURE REGULATING VALVE
5 - 3-4 COMMAND VALVE
Fig. 138 Check Balls and Strainer Location
1 - STEEL CHECK BALLS
2 - CENTRAL STRAINER
3 - STEEL CHECK BALLS
4 - PLASTIC CHECK BALLS
5 - PLAIN DOWEL PIN
VAAUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 127

(6) Install all check balls (1, 3, 4) (Fig. 138) and
the central strainer (2).
(7) Install the strainer (1) (Fig. 139) in the inlet to
torque converter lock-up control solenoid valve.
(8) Position the sealing plate (3) onto the valve
body (4) (Fig. 140).
(9) Install the valve housing (2) onto the valve
body (4) and sealing plate (3).
(10) Install the shift plate Torxtbolts (1) (Fig.
140). Tighten the bolts to 8 N´m (71 in.lbs.).
(11) Install leaf spring (5) (Fig. 140).(12) Install the strainers (1, 2) for the modulating
pressure and shift pressure control solenoid valves
(Fig. 141) into the valve housing.
Fig. 139 Converter Lock-up Solenoid Valve Strainer
Location
1 - CONVERTER LOCK-UP SOLENOID STRAINER
Fig. 140 Shift Plate Components
1-BOLTS-29
2 - VALVE HOUSING
3 - SEALING PLATE
4 - VALVE BODY
5 - LEAF SPRING
Fig. 141 Solenoid Valve Strainer Locations
1 - SOLENOID VALVE STRAINERS
21 - 128 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATIONVA

(13) Install the electrohydraulic control module
(12) onto the shift plate (13) (Fig. 142).
(14) Bend the retaining lug on stiffening rib on
transmission oil temperature sensor to retain the
electrohydraulic control module.
(15) Install the solenoid valves (6 - 11) into shift
plate (13).
NOTE: Check O-rings on solenoid valves for dam-
age and replace if necessary.
(16) Install the leaf springs (5).
(17) Install the Torxtsocket bolts (3, 4) (Fig. 142).
Tighten the bolts to 8 N´m (71 in.lbs.).
NOTE: Pay attention to the different lengths of the
TorxTsocket bolts.
(18) Install the solenoid caps (1, 2).
(19) Install the electrohydraulic unit into the vehi-
cle.
INSTALLATION
(1) Position the electrohydraulic unit in the trans-
mission housing.
(2) Insert selector valve (1) (Fig. 143) in driver of
detent plate (2). When installing the electrohydraulic
control module in the transmission housing, the plas-
tic part of the selector valve (1) must engage in the
driver of the detent plate (2).Fig. 142 Electrical Unit Components
1 - SOLENOID CAP
2 - SOLENOID CAP
3 - BOLT - M6X32
4 - BOLT - M6X30
5 - LEAF SPRING
6 - MODULATING PRESSURE REGULATING SOLENOID VALVE
7 - SHIFT PRESSURE REGULATING SOLENOID
8 - 3-4 SHIFT SOLENOID
9 - TORQUE CONVERTER LOCK-UP SOLENOID
10 - 1-2/4-5 SHIFT SOLENOID
11 - 2-3 SHIFT SOLENOID
12 - ELECTRICHYDRAULIC CONTROL MODULE
13 - SHIFT PLATE
Fig. 143 Connect The Selector Valve To The Detent
Plate
1 - SELECTOR VALVE
2 - DETENT PLATE
VAAUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 129

(3) Install the Torxtsocket bolts (3) (Fig. 144) and
torque to 8 N´m (71 in.lbs.).
(4) Install a new oil filter (4) (Fig. 144).
(5) Install oil pan (5) (Fig. 144) and torque the oil
pan bolts to 8 N´m (71 in.lbs.).
(6) Install the oil drain plug (8) (Fig. 144) with a
new drain plug gasket (9). Torque the drain plug to
20 N´m (177 in.lbs.).
(7) Install the guide bushing (2) (Fig. 144) into the
transmission housing and install the bolt (11) to hold
the guide bushing in place.(8) Check O-ring on plug connector (1) (Fig. 145),
and replace if necessary.
(9) Install the plug connector (1) into the guide
bushing (2). Turn bayonet lock of guide bushing (2)
clockwise to connect plug connector (1).
(10) Position the heat shield (2) (Fig. 146) onto the
transmission housing and install the screw (1) and
bolt (3) to hold the shield in place.
(11) Fill the transmission with the correct oil
(Refer to LUBRICATION & MAINTENANCE/FLUID
TYPES - DESCRIPTION) using the standard proce-
dure (Refer to 21 - TRANSMISSION/AUTOMATIC -
NAG1/FLUID AND FILTER - STANDARD PROCE-
DURE - TRANSMISSION FILL).
Fig. 144 Install Electrohydraulic Unit
1 - HEAT SHIELD
2 - ELECTROHYDRAULIC UNIT
3 - BOLT
4 - OIL FILTER
5 - OIL PAN
6 - CLAMPING ELEMENT
7 - BOLT
8 - DRAIN PLUG
9 - DRAIN PLUG GASKET
10 - 13-PIN PLUG CONNECTOR
11 - BOLT
12 - GUIDE BUSHING
Fig. 145 Install Wiring Connector Plug
1 - PLUG CONNECTOR
2 - GUIDE BUSHING
Fig. 146 Install Heat Shield
1 - SCREW
2 - HEAT SHIELD
3 - BOLT
21 - 130 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATIONVA

FLUID AND FILTER
DESCRIPTION
The oil level control (Fig. 147) is located on the
electrohydraulic unit (4) and consists of the float (5)
which is integrated into the electrohydraulic unit.
The float is positioned to plug the opening (6)
between the oil gallery (2) and gearset chamber (1) so
that the rotating gearsets do not splash about in oil
as the oil level rises. The oil level control reduces
power loss and prevents oil from being thrown out of
the transmission housing at high oil temperatures.
OPERATION
With low oil levels, the lubricating oil which flows
constantly out of the gearset, flows back to oil gallery
(2) though the opening (6). (Fig. 148) If the oil level
rises, the oil presses the float (5) against the housing
opening (6). The float (5) therefore separates the oil
gallery (2) from the gearset chamber (1). The lubri-
cating oil which continues to flow out of the gearsets
is thrown against the housing wall, incorporated by
the rotating parts and flows back into the oil gallery
(2) through the upper opening (arrow).
DIAGNOSIS AND TESTING
EFFECTS OF INCORRECT FLUID LEVEL
A low fluid level allows the pump to take in air
along with the fluid. Air in the fluid will cause fluid
pressures to be low and develop slower than normal.
If the transmission is overfilled, the gears churn the
fluid into foam. This aerates the fluid and causing
the same conditions occurring with a low level. In
either case, air bubbles cause fluid overheating, oxi-
dation, and varnish buildup which interferes with
valve and clutch operation. Foaming also causes fluid
expansion which can result in fluid overflow from the
transmission vent or fill tube. Fluid overflow can eas-
ily be mistaken for a leak if inspection is not careful.
Fig. 147 Fluid Level Control
1 - GEARSET CHAMBER
2 - OIL GALLERY
3 - SHELL OF ELECTROHYDRAULIC UNIT
4 - ELECTROHYDRAULIC UNIT
5 - FLOAT
6 - OPENING
Fig. 148 Fluid Level Control
1 - GEARSET CHAMBER
2 - OIL GALLERY
3 - SHELL OF ELECTROHYDRAULIC UNIT
4 - ELECTROHYDRAULIC UNIT
5 - FLOAT
6 - OPENING
VAAUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 131

CAUSES OF BURNT FLUID
Burnt, discolored fluid is a result of overheating
which has three primary causes.
1. Internal clutch slippage, usually caused by low
line pressure, inadequate clutch apply pressure, or
clutch seal failure.
2. A result of restricted fluid flow through the
main and/or auxiliary cooler. This condition is usu-
ally the result of a faulty or improperly installed
drainback valve, a damaged oil cooler, or severe
restrictions in the coolers and lines caused by debris
or kinked lines.
3. Heavy duty operation with a vehicle not prop-
erly equipped for this type of operation. Trailer tow-
ing or similar high load operation will overheat the
transmission fluid if the vehicle is improperly
equipped. Such vehicles should have an auxiliary
transmission fluid cooler, a heavy duty cooling sys-
tem, and the engine/axle ratio combination needed to
handle heavy loads.
FLUID CONTAMINATION
Transmission fluid contamination is generally a
result of:
²adding incorrect fluid
²failure to clean dipstick and fill tube when
checking level
²engine coolant entering the fluid
²internal failure that generates debris
²overheat that generates sludge (fluid break-
down)
²failure to replace contaminated converter after
repair
The use of non-recommended fluids can result in
transmission failure. The usual results are erratic
shifts, slippage, abnormal wear and eventual failure
due to fluid breakdown and sludge formation. Avoid
this condition by using recommended fluids only.
The dipstick cap and fill tube should be wiped
clean before checking fluid level. Dirt, grease and
other foreign material on the cap and tube could fall
into the tube if not removed beforehand. Take the
time to wipe the cap and tube clean before withdraw-
ing the dipstick.
Engine coolant in the transmission fluid is gener-
ally caused by a cooler malfunction. The only remedy
is to replace the radiator as the cooler in the radiator
is not a serviceable part. If coolant has circulated
through the transmission, an overhaul is necessary.
The torque converter should be replaced whenever
a failure generates sludge and debris. This is neces-
sary because normal converter flushing procedures
will not remove all contaminants.
STANDARD PROCEDURE
CHECK OIL LEVEL
(1) Verify that the vehicle is parked on a level sur-
face.
(2) Remove locking pin (1) (Fig. 149). Remove the
plate of the locking pin with a suitable tool and press
out the pin remaining in the cap downwards.
(3) Remove cap (2).
WARNING: Risk of accident from vehicle starting off
by itself when engine running. Risk of injury from
contusions and burns if you insert your hands into
the engine when it is started or when it is running.
Secure vehicle to prevent it from moving off by
itself. Wear properly fastened and close-fitting work
clothes. Do not touch hot or rotating parts.
(4) Actuate the service brake. Start engine and let
it run at idle speed in selector lever position ªPº.
(5) Shift through the transmission modes several
times with the vehicle stationary and the engine
idling
(6) Warm up the transmission, wait at least 2 min-
utes and check the oil level with the engine running.
Push the Oil Dipstick 8863A in up to the stop on the
electrohydraulic unit and pull out again, read off oil
level, repeat if necessary.
NOTE: The dipstick will protrude from the fill tube
approximately 75mm (3 inches) when installed.
Fig. 149 Remove Dipstick Tube Cap Lock
1 - LOCKING PIN
2 - TUBE CAP
3 - DIPSTICK TUBE
21 - 132 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATIONVA

(7) Check transmission oil temperature.
NOTE: The true transmission oil temperature can
only be read by a scan tool in REVERSE or any for-
ward gear position. (Refer to 21 - AUTOMATIC
TRANSMISSION- NAG1/TRANSMISSION TEMPERA-
TURE SENSOR/PARK-NEUTRAL SWITCH - OPERA-
TION)
(8) The transmission Oil Dipstick 8863A has indi-
cator marks every 10mm. Determine the height of
the oil level on the dipstick and using the height, the
transmission temperature, and the Transmission
Fluid Graph (Fig. 150), determine if the transmission
oil level is correct.
(9) Add or remove oil as necessary and recheck the
oil level.
(10) Once the oil level is correct, install a new dip-
stick tube cap (2) (Fig. 151) and lock pin (1).
TRANSMISSION FILL
Fig. 150 NAG1 Transmission Fill Graph
Fig. 151 Dipstick Tube Cap Components
1 - LOCKING PIN
2 - TUBE CAP
3 - DIPSTICK TUBE
VAAUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 133