2006 MERCEDES-BENZ SPRINTER check engine

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

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

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

CONDITION POSSIBLE CAUSES CORRECTION
NO UPSHIFT OF 1ST
GEAR AT TIMES1. Connector Ballast Unit. Output
Speed Sensor Loose, Incorrectly
Contacted.1. Check Connectors, Replace
Output Speed sensor If Neces-
sary.
2. Output Speed Sensor Defective 2. Replace Output Speed Sen-
sor.
LEAKAGE AT THE AREA
OF THE ELECTRICAL
PLUG TO THE CONDUC-
TOR PLATE1. Deformation O-Rings. 1. Replace O-Rings.
2. Deformation Adapter. 2.Replace Adaptor.
3. The Conductor Plate Is Not Fitted
Surface To Surface On The Valve
Body In One Corner, The Plug Is
Not Centered In The Socket And
The O-ring Will Not Seal.3. Remove Nose Of Conductor
Plate.
4. Contacting At The Conductor
Plate Leaky. Oil In Harness, Some-
times In The Control Module.4. Replace Conductor Plate.
LEAKAGE AT THE AREA
OF BELL HOUSING/
TORQUE CONVERTER1. Bolts (Torx M6) Outer Disc Carri-
er B1.1. Clean Thread and Install the
Bolts Using Sealer.
OIL LEAKS 1. 6 Lower Bolts (TorxM8) Converter
Housing.1. Clean Thread and Install the
Bolts Using Sealer.
2. Oil Drain Plug Converter Loose
Resp. No Seal Ring Installed.2. Install Drain Plug Correctly.
3. Weld Seam Of Torque Converter
Leaky.3. Replace Torque Converter.
4. Radial Sealing Ring Oil Pump
Defective.4. Replace Sealing Ring.
5. O-Ring Oil Pump Defective Or
Not Installed.5. Install O-Ring.
6. Bushing Of Oil Pump Loose,
caused By Missing Fit Bolt At
Transmission/Engine Flange.6. Install Fit Bolt If Necessary.
STANDARD PROCEDURE - ALUMINUM
THREAD REPAIR
Damaged or worn threads in the aluminum trans-
mission case and valve body can be repaired by the
use of Heli-CoilsŸ, or equivalent. This repair con-
sists of drilling out the worn-out damaged threads.
Then tap the hole with a special Heli-CoilŸ tap, or
equivalent, and installing a Heli-CoilŸ insert, or
equivalent, into the hole. This brings the hole back to
its original thread size.
Heli-CoilŸ, or equivalent, tools and inserts are
readily available from most automotive parts suppli-
ers.
REMOVAL
(1) Disconnect the negative (ground) battery cable.
CAUTION: Isolate ground lead to prevent accidental
contact.(2) Apply parking brake.
(3) Move gear selector lever to position ªNº.
(4) Remove oil drain plug (2) (Fig. 26) and drain
automatic transmission oil into a clean container.
21 - 42 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATIONVA

(16) Disconnect ground strap and tie back to one
side.
(17) Remove bolts (A) (Fig. 37) on underside of
transmission. Two bolts (A) on top of transmission
must remain in the housing.
(18) Place hydraulic transmission jack under
transmission and raise slightly. Secure transmission
on hydraulic jack with a strap or ask an assistant to
hold it.
(19) Remove rear engine cross member (4) (Fig.
37). First remove the nuts (5) at the outside ends of
the engine crossmember. Then remove the bolts (1) of
the transmission mount.
(20) Remove the last bolts (A, B) (Fig. 37) on the
top of the transmission.
(21) Remove the transmission towards the rear
and lower. Ensure that the converter remains in the
transmission housing when the transmission is
removed.
(22) Remove the torque converter.DISASSEMBLY
(1) Remove the torque converter (1) (Fig. 38).
(2) Place transmission in a vertical position.
(3) Measure input shaft end play as follows: (Fig.
39)
Fig. 37 Support Transmission and Remove Bolts
1 - BOLT, TRANSMISSION MOUNT
2 - UPPER SHELL FOR TRANSMISSION MOUNT
3 - TRANSMISSION MOUNT
4 - CROSSMEMBER
5 - NUT, ENGINE CROSSMEMBER
6 - NUT, TRANSMISSION SUPPORT
Fig. 38 Remove Torque Converter
1 - TORQUE CONVERTER
2 - CONVERTER HOUSING
Fig. 39 Checking Input Shaft End Play
1 - TOOL 8266-8
2 - TOOL 8266-18
3 - TOOL C-3339
21 - 46 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATIONVA

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

To avoid overfilling transmission after a fluid
change or overhaul, perform the following procedure:
(1) Verify that the vehicle is parked on a level sur-
face.
(2) Remove locking pin (1) (Fig. 152). 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).
(4) Add following initial quantity of required fluid
(Refer to LUBRICATION & MAINTENANCE/FLUID
TYPES - DESCRIPTION) to transmission:
(a) If only fluid and filter were changed, add7.4
L (14.8 pts.)of transmission fluid to transmission.
(b) If transmission was completely overhauled,
torque converter was replaced or drained, and
cooler was flushed, add7.7 L (16.3 pts.)of trans-
mission fluid to transmission.
(5) Check the transmission fluid (Refer to 21 -
TRANSMISSION/AUTOMATIC - NAG1/FLUID AND
FLUID - STANDARD PROCEDURE - CHECK OIL
LEVEL) and adjust as required.
FLUID / FILTER SERVICE
(1) Run the engine until the transmission oil
reaches operating temperature.
(2) Raise and support vehicle.
(3) Remove the torque converter drain plug access
plug from the bottom of the torque converter hous-
ing.
(4) Rotate the engine clockwise until the torque
converter drain plug (8) (Fig. 153) is aligned with the
access hole.
NOTE: Clean the area around the drain plug to pre-
vent dirt from entering the torque converter.
(5) Using a suitable drain pan to catch the fluid,
remove the torque converter drain plug (8) and allow
the torque converter to drain completely.
(6) Inspect the torque converter drain plug seal (9)
(Fig. 153). Replace the seal if necessary.
(7) Install the torque converter drain plug (8).
Tighten the drain plug to 14 N´m (10 ft.lbs.).
(8) Install the torque converter drain plug access
plug into the bottom of the torque converter housing.
(9) Using a suitable drain pan to catch the fluid,
remove the transmission oil pan drain plug (6) (Fig.
153) and allow the oil pan to drain completely.
(10) Inspect the transmission oil pan drain plug
seal (7). Replace the seal if necessary.
(11) Install the transmission oil pan drain plug (6).
Tighten the drain plug to 20 N´m (15 ft.lbs.).
(12) Remove the bolts (5) and retainers (4) (Fig.
153) holding the oil pan to the transmission.
(13) Remove the transmission oil pan (3) and gas-
ket (2) from the transmission.
Fig. 152 Remove Dipstick Tube Cap Lock
1 - LOCKING PIN
2 - TUBE CAP
3 - DIPSTICK TUBE
Fig. 153 Fluid/Filter Service Points
1 - OIL FILTER
2 - OIL PAN GASKET
3 - OIL PAN
4 - RETAINER
5 - BOLT
6 - OIL PAN DRAIN PLUG
7 - SEAL
8 - TORQUE CONVERTER DRAIN PLUG
9 - SEAL
21 - 134 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATIONVA

ASSEMBLY
NOTE: The side of the freewheeling clutch F2 (3)
with the markings (directional arrow, part number,
etc.) must be up when the clutch is installed in the
sun gear (4).
(1) Press freewheeling clutch F2 (3) (Fig. 158) into
sun gear (4).
(2) Install snap-ring (2) for freewheeling clutch.
(3) Check O-rings (6) (Fig. 158) on hollow shaft,
replace if necessary.
(4) Install rear sun gear (4) with K3 internally
toothed disc carrier and rear freewheeling clutch (3)
onto the hollow shaft.
(5) Verify proper operation of the freewheeling
clutch F2. When the assembly is held with the F2clutch snap-ring upward, it should be possible to
rotate the hollow shaft counter-clockwise.
(6) Install retaining ring (5) onto hollow shaft (1).
GEARSHIFT CABLE
DIAGNOSIS AND TESTING
GEARSHIFT CABLE
(1) The floor shifter lever and gate positions
should be in alignment with all transmission PARK,
NEUTRAL, and gear detent positions.
(2) Engine starts must be possible with floor shift
lever in PARK or NEUTRAL gate positions only.
Fig. 158 Freewheeling Clutch F2
1 - HOLLOW SHAFT 4 - K3 INNER DISC CARRIER AND REAR PLANETARY SUN
GEAR
2 - F2 CLUTCH SNAP-RING 5 - RETAINING RING
3 - FREEWHEELING CLUTCH F2 6 - O-RINGS
21 - 138 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATIONVA