2006 MERCEDES-BENZ SPRINTER Service Manual

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Page 1777 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual 2-1 Shift - First Gear Engaged
After the gear change is complete, the 1-2/4-5 shift
solenoid (1) (Fig. 22) is turned off. This reduces the
pressure on the end face of the 1-2/4-5 commandvalve (5) to 0

Page 1778 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual end face of the holding valve by the downshifted com-
mand valve. The upshifted holding valve also allows
the remaining pressure in clutch K1 (6) to be vented.
VAAUTOMATIC TRANSMISSION NAG1 - SERVICE

Page 1779 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual Gear Shift N to D (1st gear) - Engine Started
With the engine started (Fig. 23) and the gearshift
lever in the NEUTRAL or PARK positions, holding
clutch B1 (1) and driving clutch K3 (4) are applied
an

Page 1780 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual Activation Sequence
The selector valve (Fig. 24) opens the shift pres-
sure (p-S) feed connection from the ball valve (19)
with the shift valve B2 (9). With the shift valve B2
(9) in the upper positio

Page 1781 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual First Gear Engaged
The TCM monitors the activation sequence via the
speed of the input shaft, which slows down as the
frictional connection in the multiple-disc holding
clutch increases. When the spee

First Gear Engaged
The TCM monitors the activation sequence via the
speed of the input shaft, which slows down as the
frictional connection in the multiple-disc holding
clutch increases. When the speed drops to the speci-
fied level, the TCM shuts off the power to the 3-4
shift solenoid valve (10) (Fig. 25). The spring cham-
ber of the shift valve B2 (9) is depressurized and
switches downwards. This connects the line to the
opposing face of the piston B2 (6) with the pressure
holding valve (11). The pressure on the opposing face
of the piston B2 (6) drops to a residual pressure.
The working pressure (p-A) is formed and travels
via the 2-3 holding pressure shift valve, the 2-3 com-
mand valve and the ball valve (16) to multi-plate
clutch K3 (4) and via the 3-4 command valve (13) to
the end face of the 3-4 shift pressure shift valve (14).
The 3-4 shift pressure shift valve (14) is moved
against the force of the spring towards the right. Atthe same time the 3-4 solenoid valve (10) is ener-
gized. This allows shift valve pressure (p-SV) to enter
the spring chamber of the shift valve B2 (9) and to
reach the end face of the 3-4 command valve (13).
The shift valve B2 (9) is held in the upper position
and the 3-4 command valve (13) switches towards the
right. At the end face of the 3-4 shift pressure shift
valve (14) the working pressure (p-A) is replaced by
shift valve pressure (p-SV).
The 3-4 command valve (13) moves to the left.
Working pressure (p-A) travels via the holding pres-
sure shift valve (12) and the 3-4 command valve (13)
to the piston of multiple-disc holding clutch B2 (5).
Fig. 25 First Gear Engaged
1 - HOLDING CLUTCH B1 11 - PRESSURE HOLDING VALVE
2 - DRIVING CLUTCH K1 12 - 3-4 HOLDING PRESSURE SHIFT VALVE
3 - HOLDING CLUTCH B3 13 - 3-4 COMMAND VALVE
4 - DRIVING CLUTCH K3 14 - 3-4 SHIFT PRESSURE SHIFT VALVE
5 - HOLDING CLUTCH B2 PISTON 15 - 3-4 OVERLAP REGULATING VALVE
6 - HOLDING CLUTCH B2 PISTON OPPOSING FACE 16 - BALL VALVE
7 - SHIFT PRESSURE REGULATING SOLENOID 17 - 1-2/4-5 COMMAND VALVE
8 - SHIFT PRESSURE REGULATING VALVE 18 - 1-2/4-5 COMMAND VALVE
9 - SHIFT VALVE B2 19 - BALL VALVE
10 - 3-4 SHIFT SOLENOID
21 - 38 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATIONVA

Page 1782 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual DIAGNOSIS AND TESTING
AUTOMATIC TRANSMISSION
CAUTION: Before attempting any repair on a NAG1
automatic transmission, check for Diagnostic Trou-
ble Codes with the appropriate scan tool.
Transmission m

DIAGNOSIS AND TESTING
AUTOMATIC TRANSMISSION
CAUTION: Before attempting any repair on a NAG1
automatic transmission, check for Diagnostic Trou-
ble Codes with the appropriate scan tool.
Transmission malfunctions may be caused by these
general conditions:
²Poor engine performance.
²Improper adjustments.
²Hydraulic malfunctions.
²Mechanical malfunctions.
²Electronic malfunctions.
²Transfer case performance (if equipped).
Diagnosis of these problems should always begin
by checking the easily accessible variables: fluid level
and condition, gearshift cable adjustment. Then per-
form a road test to determine if the problem has been
corrected or if more diagnosis is necessary.
PRELIMINARY
Two basic procedures are required. One procedure
for vehicles that are drivable and an alternate proce-
dure for disabled vehicles (will not back up or move
forward).
VEHICLE IS DRIVABLE
(1) Check for transmission fault codes using the
appropriate scan tool.
(2) Check fluid level and condition.
(3) Adjust gearshift cable if complaint was based
on delayed, erratic, or harsh shifts.
(4) Road test and note how transmission upshifts,
downshifts, and engages.
VEHICLE IS DISABLED
(1) Check fluid level and condition.(2) Check for broken or disconnected gearshift
cable.
(3) Check for cracked, leaking cooler lines, or loose
or missing pressure-port plugs.
(4) Raise and support vehicle on safety stands,
start engine, shift transmission into gear, and note
following:
(a) If propeller shaft turns but wheels do not,
problem is with differential or axle shafts.
(b) If propeller shaft does not turn and transmis-
sion is noisy, stop engine. Remove oil pan, and
check for debris. If pan is clear, remove transmis-
sion and check for damaged driveplate, converter,
oil pump, or input shaft.
(c) If propeller shaft does not turn and transmis-
sion is not noisy, perform hydraulic-pressure test to
determine if problem is hydraulic or mechanical.
ROAD TESTING
Before road testing, be sure the fluid level and con-
trol cable adjustments have been checked and
adjusted if necessary. Verify that all diagnostic trou-
ble codes have been resolved.
Observe engine performance during the road test.
A poorly tuned engine will not allow accurate analy-
sis of transmission operation.
Operate the transmission in all gear ranges. Check
for shift variations and engine flare which indicates
slippage. Note if shifts are harsh, spongy, delayed,
early, or if part throttle downshifts are sensitive.
Slippage indicated by engine flare, usually means
clutch, overrunning clutch, or line pressure problems.
A slipping clutch can often be determined by com-
paring which internal units are applied in the vari-
ous gear ranges. The Clutch Application chart
CLUTCH APPLICATION provides a basis for analyz-
ing road test results.
CLUTCH APPLICATION
GEAR RATIO B1 B2 B3 K1 K2 K3 F1 F2
1 3.59 X* X X* X X
2 2.19 X X X* X
3 1.41 X X X
4 1.00 X X X
5 0.83 X X X X*
N N/A X X
R 3.16 X* X X X
R - Limp In 1.93 X X X
* = The shift components required during coast.
VAAUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 39

Page 1783 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual AUTOMATIC TRANSMISSION
CONDITION POSSIBLE CAUSES CORRECTION
MAXIMUM SPEED 30
km/h1. Speed Control 30 Actuated. 1. Instruct Customer.
ENGINE DIES WHEN
TRANSMISSION IS SHIFT-
ED INTO GEAR, ALSO
NOISES I

AUTOMATIC TRANSMISSION
CONDITION POSSIBLE CAUSES CORRECTION
MAXIMUM SPEED 30
km/h1. Speed Control 30 Actuated. 1. Instruct Customer.
ENGINE DIES WHEN
TRANSMISSION IS SHIFT-
ED INTO GEAR, ALSO
NOISES IN N AND/OR P1. PWM Valve Blocked. 1. Replace Valve.
2. Torque Converter Lock Up Con-
trol Valve Locked.2. Enable Movement of Valve,
Remove Particle.
LEVER IN ªPº POSITION
BLOCKED (BRAKE ACTI-
VATED)1. No Vacuum Brake Booster After
Long Immobilization, Brake Pedal
Not Fully Applied/Hard Pedal.1. Check Vacuum/ Tightness of
Brake Booster.
2. No Stoplamp Switch Signal (no
DTC IN ECM).2. Check Contact to Stoplamp
Switch. Replace Switch if Nec-
essary.
GRUMBLING, DRONING,
JERKING WHEN TCC IS
ENGAGED1. Slip Speed TCC to Low. 1. Switch Off Torque Converter
Lock Up Using DRBT. If Com-
plaint Is Not Reproduced After-
wards, Replace PWM Valve,
Set Adaption Values to Zero.
HOWLING, HUMMING
ABOVE 4000 RPM IN
EACH GEAR1. Oil Filter Blocked. 1. Replace Oil Filter.
2. Oil Pump. 2. Replace Oil Pump.
WHINING, SINGING 1. Gear Set Noises in 1st, 2nd, 5th
Gear.1. Replace Transmission..
2. Intermediate Bearing Of The
Drive Shaft At 0 km/h, Only When
Cold.2. Replace Intermediate Bear-
ing of the Drive Shaft.
9CLACKº NOISE FROM
CENTER SHIFT AREA
WHEN STOPPING OR
STARTING1. Park Lock Solenoid. 1. Replace Shift Lever Assem-
bly.
CRACKING NOISE WHEN
LOAD CYCLE1. Stick - Slip Between Joint Flange
and Collar Nut.1. Install Zinc Coated Collar
Nut Together With Washer.
CHATTERING IN CENTER
CONSOLE SHIFT WHILE
ACCELERATING1. Bushing Shift Shaft Has Too
Much Clearance.1. Replace Shifter Lever and
Cover Plate.
HARD 2-3 UPSHIFT
WHEN STEPPING OFF
THE ACCELERATOR PED-
AL1. Response Characteristic Control
Loop.1. Install K2 Disc Spring.
UPSHIFT 2-3, 3-4 SLIP-
PING1. Spring of Regulating Valve Pres-
sure control Valve Broken.1. Replace Spring.
HARD 2-1 DOWNSHIFT
WHEN COMING TO A
STOP1. Transmission (2-1 downshift) Not
Adapted.1. Re-adapt Transmission.
2. TCM Software Data. 2. Flash TCM.
3. Free Wheeling Clutch F1 Defec-
tive.Replace Free Wheeling Clutch
F1.
21 - 40 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATIONVA

Page 1784 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual CONDITION POSSIBLE CAUSES CORRECTION
HARD 3-2 DOWNSHIFT
WHEN DECELERATION
EVEN AFTER READAP-
TION1. K3 Idles. 1. Install TCM And/Or Electro-
hydraulic Control Unit.
NO RESP. DELAYED UP-
SHIFT, NO DTC1

CONDITION POSSIBLE CAUSES CORRECTION
HARD 3-2 DOWNSHIFT
WHEN DECELERATION
EVEN AFTER READAP-
TION1. K3 Idles. 1. Install TCM And/Or Electro-
hydraulic Control Unit.
NO RESP. DELAYED UP-
SHIFT, NO DTC1. Different Tire Sizes Are Mounted
On The Front Axle.1. Mount Uniform Tire Sizes
On The Front Axle.
NO UPSHIFT 3-4, 4-5 AF-
TER FAST OFF (ACCEL-
ERATOR)1. Upshift Prevention To Realize Dy-
namical Drivestyle.1. Instruct Customer.
NO UPSHIFT OF 1ST
GEAR BELOW 5000 RPM1. Gear Recognition Switch. 1. Replace Gear Recognition
Switch.
NO UPSHIFT INTO 5TH
GEAR WHEN FULL
THROTTLE OR KICK
DOWN ACTIVATION1. The Upshift 4-5 At Full Throttle or
Kick Down Never Occurs Until
Reaching Cut Off Speed. Under
These Conditions, The High Pow-
ered Vehicle Will Never Shift Into
5th Gear Below 250 km/h.1. Instruct Customer.
NO KICK DOWN SHIFT-
ING1. Accelerator Pedal Value < 95%. 1. Check Engine Control. Ad-
just As Necessary.
Engine Turns Up While 2-3
Upshift and/or Hard 3-2
Downshift1. Oil Level Too Low. 1. Check Oil Level. Add if Nec-
essary.
2. Oil Filter Not Installed. 2. Install Oil Filter.
3. Free Wheeling Clutch F2 Defec-
tive.3. Replace Free Wheeling
Clutch F2, Hollow Shaft, and
Rear Sun Gear/Inner Disc Car-
rier K3.
GRABBING 2-3 COAST-
ING UPSHIFT AND/OR
BRAKE DOWNSHIFT1. Oil Level Too Low. 1. Check Oil Level. Add if Nec-
essary.
2. Oil Filter Not Installed. 2. Install Oil Filter.
3. Control shift or Command Valve
Blocked.3. Check Each Slide Valve For
Base Position and Ease Of
Movement, Remove Particle.
4. K3 Disc Burnt, Hot Spots or
Rubbed Down.4. Replace Inner and Outer
Disc Carrier K3 And Control
Valve.
DELAYED ENGAGEMENT,
NO TRANSFER OF POW-
ER IN R AND/OR D, ALSO
AT TIMES1. Oil Level Too Low. 1. Check Oil Level. Add if Nec-
essary.
2. Recognition Switch - Selector Le-
ver Position.2. Replace Recognition Switch
Only When Intermediate Posi-
tion or Fault is Indicated.
3. Oil Filter Not Installed. 3. Install Oil Filter.
4. AEV, Delayed Pressure Build Up
On Piston B2/B3.4. Install New Shifting Proce-
dure (TCM, electrohydraulic
control unit or repair set).
5. Wrong Combination TCM/Electro-
hydraulic Control Unit.5. Check Combination TCM/
Electrohydraulic Control Unit.
Replace TCM Resp. Electrohy-
draulic Control Unit, if neces-
sary.
VAAUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 41

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