MERCEDES-BENZ SPRINTER 2006 Service Manual

INSTALLATION
Fig. 4 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 - 16 REAR AXLEVA

(1) Raise axle into position.
(2) Install plates and U-brackets (Fig. 4) and (Fig.
5) withnewnuts. Tighten nuts to 170 N´m (125 ft.
lbs.).
(3) Install propeller shaft and tighten bolts to 70
N´m (52 ft. lbs.).
NOTE: On installation of the propeller shaft, joint
arrows must be flush and must point towards the
frame floor. Tighten the propeller shaft in this posi-
tion.
(4) Install ALB lever to axle bracket and tighten
newnut 34 N´m (46 ft. lbs.).
(5) Install shock absorbers to rear axle and tighten
bolts to:
²M12 x 1.5 Bolt - 70 N´m (52 ft. lbs.)
²M14 x 1.5 Bolt - 110 N´m (81 ft. lbs.)
(6) Install stabilizer bar to axle and tighten bolts
to:
²SRW Axle - 25 N´m (18 ft. lbs.)²DRW Axle - 70 N´m (52 ft. lbs.)
(7) Install calipers with adapters and lines.
(8) Install brake hoses and hold-down clips.
(9) Install and adjust park brake cables.
(10) Install connection cable of brake pad wear
indicator and ABS sensor cable up to the relay unit
of the parking brake.
(11) Install cable ties to the park brake cables.
(12) Install ABS sensor and clamp bushing to
mounting bore.
NOTE: The right-hand ABS sensor cable is labeled
at the factory with a white tag.
(13) Attach connector cable for brake pad wear
indicator.
(14) Plug in cable of brake pad wear indicator.
(15) Install the wheels and tires.
(16) Fill axle with appropriate lubricant.
(17) Remove lifting device from under the axle.
(18) Remove support and lower vehicle.
Fig. 5 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 - 17

SPECIFICATIONS
AXLE SPECIFICATIONS
DESCRIPTION SPECIFICATION
Axle Ratio 3.73, 4.11
Ring Gear Diameter 216 mm (8.5 in.)
Ring Gear Backlash 0.10-0.15 mm (0.004-
0.006 in.)
Pinion Torque to Rotate 2.5-3.0 N´m (22-26 in.
lbs.)
Differential Bearing Pre-
load0.16 mm (0.006 in.)
SRW Differential Torque
to Rotate20-40 N´m (15-30 ft.
lbs.)
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Drain Plug 100 74 -
Fill Plug 100 74 -
Differential Cover Bolts 65 48 -
Ring Gear Bolts 180 133 -
Differential Bearing Cap
Bolts70 52 -
Differential Case Bolts 45 33 -
Axle Bearing Cap Bolts 72 53 -
Axle Grooved Nut 500 369 -
Axle Shaft Hub Nut 65 48 -
*Hub Inner Nut 300 221 -
Hub Outer Nut 250 184 -
*Follow service procedure for torque sequence.
3 - 18 REAR AXLEVA

SPECIAL TOOLS
SPECIAL TOOL CROSS-REFERENCE CHART
MB TOOL #MILLER
TOOL #DESCRIPTION
N/A C-293-PA PULLER
N/A C-293-37 ADAPTERS
N/A C-293-47 ADAPTERS
N/A C-293-3 PLUG
N/A C-3281 WRENCH
N/A C-4310 INSTALLER
N/A D-103 REMOVER
N/A MB-998805 INSTALLER
N/A 8617 INSTALLER
N/A 8992FLANGE PULL-
ER
N/A 9084 REMOVER
N/A 9275 INSTALLER
460 589 15 15
009276 INSTALLER
741 589 00 35
009277 PLATE
741 589 01 15
009278 INSTALLER
460 589 01 07
009279 WRENCH
309 589 01 07
009290 WRENCH
389 589 02 15
009291 INSTALLER
N/A 9317 ADAPTERS
N/A 9523 INSTALLER
N/A 9548 INSTALLER
460 589 11 15
009744 TORQUE TOOL
PULLER/PRESS C-293-PA
ADAPTER PLUG C-293-3
ADAPTERS C-293-37
ADAPTERS C-293-47
HOLDER C-3281
INSTALLER C-4310
VAREAR AXLE 3 - 19

REMOVER D-103
SCOOTER BLOCK D-115-2A
INSTALLER 6448A
INSTALLER 8617
FLANGE PULLER 8992
REMOVER 9084
INSTALLER 9275
INSTALLER 9276
3 - 20 REAR AXLEVA

PLATE 9277
INSTALLER 9278
WRENCH 9279
WRENCH 9290
INSTALLER 9291
SPREADER ADAPTERS 9317
INSTALLER 9523
VAREAR AXLE 3 - 21

DIAL INDICATOR 9524
INSTALLER 9548
ARBOR DISC 9571
PINION BLOCK 9572
DUMMY BEARING 9573
3 - 22 REAR AXLEVA

SHAFT - AXLE SINGLE REAR WHEEL
REMOVAL-SINGLE REAR WHEEL
(1) Remove wheels.
(2) Detach front brake cable.
(3) Pull ABS sensor (18) together with clamp bush-
ing (19) out of bearing cap (Fig. 6).
(4) Remove brake caliper (16) and disk (10) at rear
axle (14). Attach brake caliper with lines connected
in wheel house.
(5) Remove brake shoes (2) of parking brake.
(6) Remove brake control cable lock.
(7) Remove bearing cap bolts (17) and pull axle
shaft out of axle tube (1) (Fig. 6).
(8) Remove seal/gasket.
Fig. 6 AXLE SHAFT
1 - REAR AXLE 11 - BOLT
2 - BRAKE SHOE 12 - WHEEL BOLT
3 - PRESSURE SPRING 13 - BRAKE ADJUSTER
4 - RETURN SPRING 14 - REAR AXLE SHAFT
5 - RETURN SPRING 15 - GASKET
6 - CABLE LOCK 16 - BRAKE CABLE
7 - PARK BRAKE CABLE 17 - BOLT
8 - LOCKING PIN 18 - ABS SENSOR
9 - BOLT 19 - SENSOR BUSHING
10 - BRAKE DISC
VAREAR AXLE 3 - 23

INSTALLATION - SINGLE REAR WHEEL
(1) Install sealing ring.
(2) Install axle shaft (1) in the axle tube (2) (Fig.
7).
(3) Installnewbearing cap (2) bolts (1) and
tighten to 72 N´m (53 ft. lbs.) (Fig. 8).
NOTE: Tighten bolts diagonally across.
(4) Install brake control cable lock.
(5) Install parking brake shoes.
(6) Install brake disk and calipers.
(7) Coat clamping bush with acid-free grease.
Insert ABS sensor with clamping bush fully into the
mounting hole.
(8) Install front brake cable.(9) Operate brake pedal several times until brake
pads contact brake discs (brake pressure built up).
(10) Install wheels.
BEARING / SEAL - AXLE
REMOVAL
(1) Remove rear axle shaft.
(2) With a punch (2) and hammer straighten bear-
ing (4) nut (1) locking ring (3) (Fig. 9).
(3) Install two wheel mounting bolts into the axle
shaft (1) and clamp in vise. Loosen bearing (4) nut
(2) with Wrench 9279 (3) (Fig. 10).
Fig. 7 AXLE SHAFT AND TUBE
1 - AXLE SHAFT
2 - AXLE TUBE
3 - AXLE BEARINGS
4 - DUST SHIELD
Fig. 8 BEARING CAP BOLTS
1 - BEARING CAP BOLTS
2 - BEARING CAP
3 - AXLE SHAFT FLANGE
Fig. 9 LOCKING RING
1 - BEARING NUT
2 - PUNCH
3 - LOCKING RING
4 - BEARING
Fig. 10 BEARING NUT WRENCH
1 - AXLE SHAFT
2 - BEARING NUT
3 - WRENCH
4 - BEARING
3 - 24 REAR AXLEVA

NOTE: Bearing nut with groove on left rear axle
shaft has a left-hand thread. Bearing nut without
groove on right rear axle shaft has a right-hand
thread.
(4) Remove bearing nut (1) and locking ring (2)
from axle shaft (Fig. 11).
(5) Push Plate 9277 (2) between bearing cover and
axle shaft (1) (Fig. 12).(6) Place axle shaft (1) with plate (3) in a press.
(7) Press axle shaft (1) through the bearing cover
and tapered roller bearings (2) (Fig. 13).
(8) Remove tapered roller bearings (6), sealing ring
(7), dust shield (5) and bearing cover (2) from axle
shaft (1) (Fig. 14).
(9) Remove shaft seal (3) from bearing cover (2)
with a hammer and drift.
Fig. 11 BEARING NUT AND LOCKING RING
1 - BEARING NUT
2 - LOCKING RING
Fig. 12 AXLE BEARING REMOVAL TOOL
1 - AXLE SHAFT
2 - PLATE
Fig. 13 PRESSING BEARING
1 - AXLE SHAFT
2 - BEARING
3 - PLATE
Fig. 14 AXLE SHAFT ASSEMBLY
1 - AXLE SHAFT 6 - BEARING
2 - BEARING COVER 7 - SEALING RING
3 - RADIAL SHAFT SEAL 8 - LOCKING RING
4 - GASKET 9 - BEARING NUT
5 - DUST SHIELD
VAREAR AXLE 3 - 25