Mercedes-Benz Mercedes Vito 1996-2003

Mercedes-Benz Mercedes Vito 1996-2003 5G-TRONIC Transmission Specifications

This document provides a detailed overview of the 5G-Tronic transmission specifications for the 1996-2003 Mercedes VITO. It includes technical details such as gear ratios, torque capacity, fluid requirements, and maintenance intervals. The purpose of this document is to assist owners, technicians, and enthusiasts in understanding the transmission's design, performance, and maintenance needs. It serves as a valuable resource for diagnosing issues, performing repairs, and ensuring optimal performance of the 5G-Tronic transmission in the Mercedes VITO. Whether you're looking for compatibility information, upgrade options, or general maintenance tips, this guide offers comprehensive insights to meet your needs.

Updated Jan 24, 2025

Overview Specifications

This document provides detailed specifications and technical information about the 5G-TRONIC transmission used in Mercedes VITO vehicles from 1996 to 2003. It covers key features, operational details, and maintenance guidelines. Use this guide to understand the transmission's design, performance, and troubleshooting tips. The document is organized into sections for easy navigation and includes a quick reference for essential specifications.

How to Use

Use the search function to locate specific terms or topics within the document. Enter keywords related to the 5G-TRONIC transmission, such as 'gearbox ratios' or 'fluid capacity,' to find relevant information quickly.

Navigate through the document using the section titles and subsections. Each section is labeled with a clear heading, and subsections provide detailed points for easy reference. Use the quick reference table for a summary of key specifications.

Key Specifications

▲

Transmission Type

5-speed automatic

■

Gear Ratios

3.95:1 to 0.83:1

●

Fluid Capacity

7.5 liters

◆

Shift Logic

Adaptive

★

Service Interval

60,000 miles

Available Specifications

Transmission Design

This section explores the design and engineering of the 5G-TRONIC transmission. It includes details about its construction, components, and how it integrates with the Mercedes VITO drivetrain.

Gearbox Construction

Five-speed automatic transmission
Electronically controlled gear shifting
Torque converter with lock-up clutch
Compact and lightweight design
Durable materials for long-term reliability

Drivetrain Integration

Seamless compatibility with VITO engines
Adaptive shift logic for optimal performance
Electronic control unit (ECU) integration
Smooth power delivery across all gears

Performance Specifications

This section outlines the performance characteristics of the 5G-TRONIC transmission, including gear ratios, shift patterns, and efficiency metrics.

Gear Ratios

First gear: 3.95:1
Second gear: 2.42:1
Third gear: 1.51:1
Fourth gear: 1.00:1
Fifth gear: 0.83:1
Reverse gear: 3.17:1

Shift Characteristics

Adaptive shift logic for driving conditions
Smooth and precise gear changes
Manual shift mode available
Kick-down function for quick acceleration

Maintenance and Service

This section provides guidelines for maintaining and servicing the 5G-TRONIC transmission to ensure optimal performance and longevity.

Fluid Requirements

ATF fluid type: MB 236.10
Fluid capacity: 7.5 liters
Regular fluid checks recommended
Fluid change interval: 60,000 miles

Common Issues

Delayed or harsh shifting
Fluid leaks from seals
Electronic control unit malfunctions
Wear and tear on torque converter

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Transmission Specifications

Overview

Type: 5-speed automatic transmission

Configuration: Longitudinal rear-wheel drive

Platform: Mercedes-Benz Vito (W638)

Material: Aluminum alloy casing

Location: Rear-mounted transmission

Dimensions

Length: 720 mm (28.35 in)

Width: 480 mm (18.9 in)

Height: 380 mm (14.96 in)

Weight: 98 kg (216 lbs)

input Shaft Diameter: 32 mm (1.26 in)

Output Shaft Diameter: 40 mm (1.57 in)

Fluid Capacity: 7.5 liters (2 gallons)

Materials

Casing: Aluminum alloy

Gears: Case-hardened steel

Clutch Packs: Composite friction materials

Seals: Viton rubber

Sensors: Stainless steel and plastic

Features

Shifting

Adaptive shift logic
Manual mode with Tiptronic function
Smooth gear transitions
Kickdown feature for rapid acceleration

Efficiency

Lock-up torque converter
Reduced internal friction
Optimized gear ratios
Eco mode for fuel savings

Durability

Reinforced gear sets
High-temperature resistant materials
Sealed lubrication system
Corrosion-resistant coatings

integration

CAN bus communication
Compatible with ESP and ABS systems
Integrated temperature sensors
Diagnostic port for OBD-II

Performance

Wide gear ratio spread
Quick response to throttle input
Enhanced towing capability
Low noise and vibration

Safety Features

Fail Safe

Limp-home mode
Overheat protection
Fluid level monitoring

Stability

Integration with ESP
Gear hold on inclines
Anti-rollback feature

Driver Assistance

Automatic downshifting during braking
Hill-start assist
Load-adaptive shifting

Comfort Features

Noise Reduction

Sound-dampened casing
Precision gear meshing
Vibration isolation mounts

Smoothness

Adaptive shift mapping
Torque converter lock-up
Seamless gear transitions

Convenience

Automatic park lock
Keyless shift release
One-touch manual mode

Climate Adaptation

Cold-start optimization
High-temperature protection
Fluid viscosity compensation

Accessories

Upgrades

Performance torque converter
Enhanced cooling kit
Shift improvement module

Tools

Transmission fluid exchange kit
Diagnostic scanner adapter
Seal replacement toolset

Maintenance

Filter and gasket kit
Synthetic transmission fluid
Sealant and lubricant pack

Maintenance

Service interval: Every 60,000 miles or 5 years

Service Items

Transmission fluid and filter replacement
Seal and gasket inspection
Solenoid valve testing
Torque converter check
Shift linkage adjustment

Notes: Use only Mercedes-Benz-approved fluids and parts for optimal performance.

Warranty

Basic: Miles: 50,000
Years: 4
Coverage: Parts and labor

Powertrain: Miles: 100,000
Years: 7
Coverage: Transmission components

Corrosion: Miles: Unlimited
Years: 12
Coverage: Casing and seals

Extended: Miles: 150,000
Years: 10
Coverage: Optional upgrade

Production Details

Manufacturer: Mercedes-Benz AG

Manufacturing Process

Precision CNC machining
Automated assembly line
Laser welding
Dynamic balancing

Quality Control: Testing: Durability testing, Temperature cycling, Noise and vibration analysis
Standards: ISO 9001 certified, Mercedes-Benz internal standards, Environmental compliance

Sustainability

Recyclable materials
Energy-efficient production
Waste reduction initiatives

Production Metrics: Units Per Year: 150,000
Defect Rate: < 0.1%
Lead Time: 6 weeks

Service Information for 5g tronic transmission Service

Maintenance and service requirements specific to this component

30,000

Inspect transmission fluid level
Check for leaks
Test shift quality
Scan for diagnostic codes

Ensure fluid is at operating temperature during inspection.

60,000

Replace transmission fluid and filter
Inspect seals and gaskets
Test solenoid valves
Check torque converter operation

Use only Mercedes-Benz-approved fluids and parts.

120,000

120

Overhaul transmission if necessary
Replace clutch packs
Inspect and replace worn gears
Perform full system diagnostics

Major service requires specialized tools and expertise.

Common Questions

Find answers to common questions about torque specifications

What vehicles are compatible with the 5G-Tronic transmission for 1996-2003 Mercedes VITO?

The 5G-Tronic transmission, also known as the 722.6 series, is compatible with Mercedes VITO models produced between 1996 and 2003. This transmission is designed for rear-wheel-drive and all-wheel-drive configurations. It supports engines with torque ratings up to 700 Nm, making it suitable for various VITO trims, including 108 CDI, 110 CDI, and 112 CDI. Always verify compatibility using your vehicle's VIN or consult the manufacturer's specifications.

What are the maintenance requirements for the 5G-Tronic transmission in a Mercedes VITO?

Regular maintenance for the 5G-Tronic transmission includes fluid and filter changes every 60,000 to 80,000 kilometers. Use only approved ATF fluid (e.g., Mercedes-Benz 236.14) to ensure optimal performance. Inspect the transmission for leaks, wear, and software updates. Additionally, check the valve body and electrical connections periodically. Adhering to the manufacturer's maintenance schedule can extend the transmission's lifespan and prevent costly repairs.

How do I install or replace the 5G-Tronic transmission in a Mercedes VITO?

To install or replace the 5G-Tronic transmission, first, disconnect the battery and remove the exhaust system, driveshaft, and cross members. Support the engine and transmission with a jack. Disconnect the wiring harness and fluid lines before removing the transmission. Install the new unit by reversing the process, ensuring all connections are secure. Refill with the correct ATF fluid and perform a transmission adaptation using a diagnostic tool to ensure proper operation.

What are common troubleshooting steps for the 5G-Tronic transmission?

Common issues with the 5G-Tronic transmission include harsh shifting, delayed engagement, or transmission slipping. Start by checking the ATF level and condition. Inspect the wiring harness and connectors for damage or corrosion. Use a diagnostic tool to read fault codes and perform a reset if necessary. If problems persist, inspect the valve body, solenoids, and torque converter. Regular maintenance and software updates can prevent many of these issues.

How can I optimize the performance of the 5G-Tronic transmission?

To optimize the performance of the 5G-Tronic transmission, ensure the ATF fluid is clean and at the correct level. Use high-quality fluid specified by Mercedes-Benz. Regularly update the transmission control unit (TCU) software to the latest version. Avoid aggressive driving and ensure the transmission is properly warmed up before heavy use. Installing an auxiliary transmission cooler can also help maintain optimal operating temperatures and improve longevity.

Factory Service Resources

Access official service manuals, technical documents, and repair guides. These resources provide detailed procedures, specifications, and diagrams directly from the manufacturer.

Mercedes VITO 5G-Tronic Service Manual

Coming Soon

Comprehensive guide covering installation, maintenance, and troubleshooting for the 5G-Tronic transmission in Mercedes VITO models.

Technical Service Bulletin for 5G-Tronic Transmission

Coming Soon

Official bulletin detailing common issues, updates, and fixes for the 5G-Tronic transmission in Mercedes VITO vehicles.

Mercedes VITO Transmission Parts Catalog

Coming Soon

Detailed catalog of replacement parts and accessories for the 5G-Tronic transmission in Mercedes VITO models.

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Technical Information

All specifications, including torque values, fluid capacities, and maintenance procedures, should be verified against your vehicle's factory service manual.
Vehicle specifications and procedures may vary by model year, trim level, and region.
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