MERCEDES-BENZ SPRINTER 2006 Service Manual

SPECIFICATIONS
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Propeller shaft to trans-
mission bolt70 52 -
Propeller shaft to axle
bolt70 52 -
Retaining bracket to
frame floor bolt100 74 -
Center Bearing support to
frame floor bolt95 70 -
Center Bearing to support
nut105 77 -
SPECIAL TOOLS
SPECIAL TOOL CROSS-REFERENCE CHART
MB TOOL #MILLER TOOL
#DESCRIPTION
N/A 938 BRIGE
N/A 1130 SPLITTER
387 589 05 15
009275 INSTALLER
N/A 7663INCLINOME-
TER
Fig. 5 UNIVERSAL JOINT ANGLE
1 - YOKES MUST BE IN SAME PLANE
BRIDGE 938
3 - 6 PROPELLER SHAFTVA

PROPELLER SHAFT
REMOVAL
(1) Secure vehicle to prevent it from rolling.
(2) Make installing reference marks on propeller
shaft (Fig. 6) and (Fig. 7).
(3) Remove retaining bracket bolts (Fig. 8) and
(Fig. 9).
(4) Remove propeller shaft bolts from rear axle
and transmission at the flange.
(5) Remove propeller shaft intermediate bearing
nuts from retaining bracket and bracket for brake
cable.
NOTE: The brake cable bracket is only installed in
vehicles with wheelbase 3550 mm
SPLITTER 1130
INSTALLER 9275
INCLINOMETER 7663
Fig. 6 ALIGNMENT MARKS
1 - ALIGNMENT MARK
2 - BOOT
3 - ALIGNMENT MARK
4 - CENTER BEARING
Fig. 7 ALIGNMENT MARKS 3 PIECE SHAFT
1 - REFERNCE MARK
2 - CENTER SHAFT
3 - REFERENCE MARK
4 - REAR SHAFT
VAPROPELLER SHAFT 3 - 7

Fig. 8 2 PIECE PROPELLER SHAFT
1 - FLANGE BOLT 6 - NUT
2 - BEARING 7 - BRACKET
3 - PROPELLER SHAFT 8 - RETAINING BRACKET
4 - REAR AXLE 9 - COLLARED BOLT
5 - CABLE BRACKET 10 - TRANSMISSION
3 - 8 PROPELLER SHAFTVA

(6) Remove shaft from the vehicle.
INSTALLATION
(1) Install propeller shaft intermediate bearing/
bearings to support and tighten nuts to 105 N´m (77
ft. lbs.).
(2) Install propeller shaft intermediate bearing
support/supports to frame floor and tighten bolts to
95 N´m (70 ft. lbs.).
(3) Install propeller shaft intermediate bearing
with retaining bracket and bracket for brake cable.
NOTE: The bracket is only installed on vehicles
with wheelbase 3550 mm.
(4) Install propeller shaft to rear axle and trans-
mission flange with installation marks are aligned.
Tighten bolts to 70 N´m (66 ft. lbs.).
(5) Install retaining bracket and tighten bolts to
100 N´m (74 ft. lbs.).
CENTER BEARING
REMOVAL
(1) Remove propeller shaft.
(2) Mark shafts for installation alignment (Fig.
10).(3) Loosen both collar clamps (Fig. 11).
Fig. 9 3 PIECE PROPELLER SHAFT
1 - FLANGE BOLT 7 - BRACKET
2 - INTERMEDIATE BEARING 8 - RETAINING BRACKET
3 - CENTER SHAFT 9 - BOLT
4 - REAR SHAFT 10 - FRONT SHAFT
5 - REAR AXLE 11 - TRANSMISSION
6 - NUT
Fig. 10 ALIGNMENT MARKS
1 - ALIGNMENT MARK
2 - BOOT
3 - ALIGNMENT MARK
4 - CENTER BEARING
VAPROPELLER SHAFT 3 - 9

(4) Pull apart propeller shaft.
(5) Remove snap-ring (Fig. 12).
NOTE: If center bearing is equipped with a round
flange remove bolt from the middle of the flange.
(6) Pull off center bearing with a Bearing Splitter
1130 and Bridge 938, with a plug on the end of the
shaft (Fig. 13).
NOTE: The bearing splitter must be positioned
behind the thrust washer of the bearing.
INSTALLATION
(1) Press center bearing on propeller shaft with
protective caps and washer with Installer 9275 (Fig.
14).
Fig. 11 BOOT
1 - BOOT
2 - CLAMP
3 - SHAFT
Fig. 12 CENTER BEARING
1 - SNAP-RING
2 - CENTER BEARING
3 - WASHER
4 - SHAFT
5 - PROTECTIVE CAP
Fig. 13 CENTER BEARING REMOVAL
1 - BRIDGE
2 - PLUG
3 - BEARING SPLITTER
4 - CENTER BEARING
Fig. 14 CENTER BEARING INSTALLATION
1 - INSTALLER
2 - CENTER BEARING
3 - 10 PROPELLER SHAFTVA

NOTE: If center bearing is equipped with a round
flange install new bolt in middle of the flange and
tighten to 95 N´m (70 ft. bls.).
(2) Install snap-ring.
(3) Coat propeller shaft spline with universal
grease.
(4) Push rubber boot onto propeller shaft.
(5) Push together propeller shaft. Pay attention to
alignment markings for installation position.
(6) Ensure rubber seal is correctly installed and
attachnewcollar clamps.
(7) Install propeller shaft.
VAPROPELLER SHAFT 3 - 11

REAR AXLE
TABLE OF CONTENTS
page page
REAR AXLE
DIAGNOSIS AND TESTING................12
STANDARD PROCEDURE - DRAIN AND FILL . . 13
REMOVAL.............................14
INSTALLATION.........................16
SPECIFICATIONS.......................18
SPECIAL TOOLS.......................19
SHAFT-AXLE SINGLE REAR WHEEL
REMOVAL-SINGLE REAR WHEEL..........23
INSTALLATION-SINGLE REAR WHEEL.......24
BEARING/SEAL-AXLE
REMOVAL.............................24
INSTALLATION.........................26
SHAFT-AXLE DUAL REAR WHEELS
REMOVAL-DUAL REAR WHEEL............27
INSTALLATION-DUAL REAR WHEEL........28
BEARING/SEAL-AXLE HUB
REMOVAL.............................28
INSTALLATION.........................29DIFFERENTIAL
REMOVAL.............................31
DISASSEMBLY
DISASSEMBLY-SINGLE REAR WHEEL.....32
DISASSEMBLY-DUAL REAR WHEEL.......33
ASSEMBLY
ASSEMBLY-SINGLE REAR WHEEL........34
ASSEMBLY-DUAL REAR WHEEL..........36
INSTALLATION.........................37
BEARINGS-DIFFERENTIAL CASE
REMOVAL.............................38
INSTALLATION.........................38
SEAL-PINION
REMOVAL.............................39
INSTALLATION.........................40
GEAR-PINION/RING
REMOVAL.............................41
INSTALLATION.........................42
REAR AXLE
DIAGNOSIS AND TESTING
NOTE: Axle seals, axle bearings, pinion seals and
differential cover are the only serviceble compo-
nents. If differential is damaged/noisy the axle must
be replaced.
GEAR NOISE
Axle gear noise can be caused by insufficient lubri-
cant, incorrect backlash, incorrect pinion depth, tooth
contact, worn/damaged gears, or the carrier housing
not having the proper offset and squareness.
Gear noise usually happens at a specific speed
range. The noise can also occur during a specific type
of driving condition. These conditions are accelera-
tion, deceleration, coast, or constant load.
When road testing, first warm-up the axle fluid by
driving the vehicle at least 5 miles and then acceler-
ate the vehicle to the speed range where the noise is
the greatest. Shift out-of-gear and coast through the
peak-noise range. If the noise stops or changes
greatly:
²Check for insufficient lubricant.
²Incorrect ring gear backlash.
²Gear damage.
Differential side gears and pinions can be checked
by turning the vehicle. They usually do not causenoise during straight-ahead driving when the gears
are unloaded. The side gears are loaded during vehi-
cle turns. A worn pinion shaft can also cause a snap-
ping or a knocking noise.
BEARING NOISE
The axle shaft, differential and pinion bearings can
all produce noise when worn or damaged. Bearing
noise can be either a whining, or a growling sound.
Pinion bearingshave a constant-pitch noise. This
noise changes only with vehicle speed. Pinion bearing
noise will be higher pitched because it rotates at a
faster rate. Drive the vehicle and load the differen-
tial. If bearing noise occurs, the rear pinion bearing
is the source of the noise. If the bearing noise is
heard during a coast, the front pinion bearing is the
source.
Differential bearings usually produce a low pitch
noise. Differential bearing noise is similar to pinion
bearing noise. The pitch of differential bearing noise
is also constant and varies only with vehicle speed.
Axle shaft bearingsproduce noise and vibration
when worn or damaged. The noise generally changes
when the bearings are loaded. Road test the vehicle.
Turn the vehicle sharply to the left and to the right.
This will load the bearings and change the noise
level. Where axle bearing damage is slight, the noise
is usually not noticeable at speeds above 30 mph.
3 - 12 REAR AXLEVA

LOW SPEED KNOCK
Low speed knock is generally caused by a worn
U-joint or by worn side-gear thrust washers. A worn
pinion shaft bore will also cause low speed knock.
VIBRATION
Vibration at the rear of the vehicle is usually
caused by a:
²Damaged drive shaft.
²Missing drive shaft balance weight(s).
²Worn or out-of-balance wheels.
²Loose wheel lug nuts.
²Worn U-joint(s).
²Loose/broken springs.
²Damaged axle shaft bearing(s).
²Loose pinion gear nut.
²Excessive pinion yoke run out.
²Bent axle shaft(s).
Check for loose or damaged front-end components
or engine/transmission mounts. These components
can contribute to what appears to be a rearend vibra-
tion. Do not overlook engine accessories, brackets
and drive belts.
NOTE: All driveline components should be exam-
ined before starting any repair.
DRIVELINE SNAP
A snap or clunk noise when the vehicle is shifted
into gear (or the clutch engaged), can be caused by:
²High engine idle speed.
²Transmission shift operation.
²Loose engine/transmission/transfer case mounts.
²Worn U-joints.
²Loose spring mounts.
²Loose pinion gear nut and yoke.
²Excessive ring gear backlash.
²Excessive side gear to case clearance.
The source of a snap or a clunk noise can be deter-
mined with the assistance of a helper. Raise the vehi-
cle on a hoist with the wheels free to rotate. Instruct
the helper to shift the transmission into gear. Listen
for the noise, a mechanics stethoscope is helpful in
isolating the source of a noise.
STANDARD PROCEDURE - DRAIN AND FILL
NOTE: Drain oil when warm.
(1) Clean area around oil fill plug and drain plug.
(2) Remove oil drain plug (2) and drain oil (Fig. 1).
(3) Install oil drain plug and tighten to N´m 100
(74 ft. lbs.).
(4) Remove oil fill plug (1) and fill housing up to
bottom edge of oil fill hole (Fig. 1).
(5) Install oil fill plug and tighten to N´m 100 (74
ft. lbs.).
Fig. 1 FILL PLUG
1 - FILL PLUG
2 - DRAIN PLUG
VAREAR AXLE 3 - 13

REMOVAL
Fig. 2 SINGLE REAR WHEEL AXLE
1 - REAR SPRING 12 - WEAR INDICATOR CONNECTOR
2 - U-BRACKET 13 - BRAKE HOSE
3 - PLATE 14 - WHEEL BOLT
4 - NUT 15 - BOLT
5 - BRAKE CABLE 16 - NUT
6 - REAR AXLE 17 - PROPELLER SHAFT
7 - ABL LEVER 18 - BOLT
8 - NUT 19 - ABS SENSOR
9 - SHOCK ABSORBER 20 - SENSOR BUSHING
10 - BOLT 21 - VENT LINE
11 - WEAR INDICATOR CABLE
3 - 14 REAR AXLEVA

(1) Raise and support the vehicle.
(2) Position a suitable lifting device under the axle
and secure axle to device.
(3) Remove wheels and tires.
(4) Unplug wear indicator cable (Fig. 2) and (Fig.
3).
(5) Detach cable connector for brake pad wear
indicator.
(6) Remove ABS sensor and clamp bushing from
mounting bore.
NOTE: The right-hand ABS sensor cable is labeled
at the factory with a white tag.
(7) Remove cable ties from the park brake cables.
Release connection cable of brake pad wear indicator
and ABS sensor cable up to the relay unit of the
parking brake.
(8) Remove brake cables.
(9) Remove hand brake cable at relay unit.(10) Remove bracket for brake cables at rear axle
tube.
(11) Remove stabilizer bar from axle brackets.
(12) Remove shock absorber bolts from rear axle.
(13) Remove ALB lever from rear axle bracket.
(14) Pull vent line of rear axle out of frame.
(15) Remove propeller shaft.
(16) Remove brake calipers.
(17) Remove U-brackets and plates (Fig. 2) and
(Fig. 3).
(18) Remove axle from the vehicle.
Fig. 3 DUAL REAR WHEEL AXLE
1 - SPRING 12 - BRAKE HOSE
2 - SPRING SHACKLE 13 - LUG NUT
3 - PLATE 14 - NUT
4 - COLLAR NUT 15 - WASHER
5 - BRAKE CABLE 16 - BOLT
6 - REAR AXLE 17 - SHOCK ABSORBER
7 - ALB LEVER 18 - PROPELLER SHAFT
8 - NUT 19 - BOLT
9 - BOLT 20 - ABS SENSOR
10 - WEAR INDICATOR CABLE 21 - SENSOR BUSHING
11 - WEAR INDICATOR CONNECTOR
VAREAR AXLE 3 - 15