MERCEDES-BENZ SPRINTER 2006 Service Manual

INSTALLATION
(1) Clean sealing surface of bearing cap.
(2) Install axle shaft seal into bearing cover (1)
with Installer 9278 (2) (Fig. 15).
NOTE: Install flush to a max. 3 mm (0.12 in.) deep
inside the bearing cover.
(3) Check roller bearing (1), and replace if neces-
sary.
NOTE: Thoroughly grease roller bearings prior to
installation with Mopar High Temp Light Bearing
Grease.
(4) Install bearing cover with axle shaft seal,new
gasket and dust shield on the axle shaft.
(5) Install tapered roller bearings (1) and race (2)
on the axle shaft (Fig. 16).(6) Installnewlocking ring (1) on axle shaft (2).
NOTE: The flat side of the locking ring must point
towards the nut (Fig. 17). The locking ring is fitted
to ensure the pressing is done over the inner bear-
ing race only. The flat on the locking ring must be
aligned with the flat on the axle shaft otherwise the
axle shaft will be damaged.
(7) Place axle shaft (2) through the hole in Plate
9277 (3) and position the assembly in a press (1)
(Fig. 18).
(8) Press tapered roller bearing onto rear axle
shaft as far as the stop.
CAUTION: In order to avoid damaging the bearing,
the outer race must be turned while pressing on.
Fig. 15 SEAL INSTALLER
1 - INSTALLER
2 - BEARING COVER
Fig. 16 BEARINGS AND RACE
1 - BEARINGS
2 - RACE
Fig. 17 BEARING AND SHAFT
1 - LOCKING RING
2 - AXLE SHAFT
3 - BEARING
4 - DUST SHIELD
Fig. 18 PRESSING AXLE SHAFT
1 - PRESS
2 - AXLE SHAFT
3 - PLATE
3 - 26 REAR AXLEVA

(9) Screw on bearing nut (1) and tighten nut with
Wrench 9279 to 500 N´m (369 ft. lbs.).
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.
(10) Bend locking ring (3) with a hammer and
punch at both grooves in the bearing nut (Fig. 19).
NOTE: The grooved nut must be locked in both
directions of rotation.
(11) Install sealing ring (4) onto roller bearing race
(Fig. 19).
(12) Install rear axle shaft.
SHAFT - AXLE DUAL REAR
WHEELS
REMOVAL - DUAL REAR WHEEL
(1) Remove wheels
(2) Remove axle shaft (2) hub (1) nuts (3) (Fig. 20).
(3) Pull out axle shaft.
Fig. 19 LOCKING RING
1 - BEARING NUT
2 - BEARING
3 - LOCKING RING
4 - SEALING RING
Fig. 20 AXLE SHAFT
1 - WHEEL HUB
2 - AXLE SHAFT
3 - AXLE NUT
VAREAR AXLE 3 - 27

INSTALLATION - DUAL REAR WHEEL
(1) Coat axle shaft flange with Mopar Metal
Assembly Paste.
(2) Slide axle shaft (2) into axle tube.
(3) Install axle shaft hub (1) nuts (3) and tighten
to N´m 65 (48 ft. lbs.) (Fig. 21).
(4) Install wheels.
BEARING / SEAL - AXLE HUB
REMOVAL
(1) Remove brake caliper with support.
(2) Remove axle shaft.
(3) Back-off parking brakes.
(4) Remove outer hub nut (1) with Wrench 9290
(Fig. 22).
(5) Remove locking plate (2), inner hub nut (1) and
thrust washer (3) (Fig. 22).
CAUTION: Thrust washer is designed for left or
right side and are not interchangeable.
(6) Pull hub off axle tube.
Fig. 21 AXLE SHAFT
1 - WHEEL HUB
2 - AXLE SHAFT
3 - AXLE NUT
Fig. 22 HUB NUTS
1 - NUTS
2 - LOCKING PLATE
3 - THRUST WASHER
3 - 28 REAR AXLEVA

(7) Pry out ABS sensor ring (1) and seal (2) from
hub (Fig. 23).
(8) Remove hub bearings (1) (3) from hub (2) (Fig.
24).
(9) Remove inner and outer bearing cups from hub
with a hammer and drift.
INSTALLATION
(1) Install hub bearing cups with Installer 9291
and a hammer.
(2) Clean and thoroughly grease bearings with
Multi-purpose grease.
(3) Install inner wheel bearing.
(4) Coat outer circumference ofnewseal (2) with
Hylomar SQ 32 M sealant.
CAUTION: Do not coat seals rubberized sealing sur-
faces with sealant.
(5) Install seal (2) into hub with an appropriate
installer.
NOTE: Seal ring should be flush with wheel hub or
max. 3mm (0.12 in.) deep.
(6) Coat contact surface of ABS sensor ring (1)
with Hylomar SQ 32 M sealant (Fig. 25).
(7) Drive ABS sensor ring (1) in as far as the stop
with a plastic hammer (Fig. 25).
(8) Install hub on axle tube.
Fig. 23 SENSOR RING & OIL SEAL
1 - ABS SENSOR RING
2 - SEAL
Fig. 24 AXLE HUB BEARINGS
1 - REAR BEARING
2 - HUB
3 - FRONT BEARING
4 - ROTOR
Fig. 25 SENSOR RING & OIL SEAL
1 - ABS SENSOR RING
2 - SEAL
VAREAR AXLE 3 - 29

(9) Install outer hub (1) bearing (2) (Fig. 26).
(10) Install thrust washer (2) (Fig. 27).
CAUTION: Thrust washer is designed for left or
right side and are not interchangeable.(11) Install inner hub (1) nut (2) (Fig. 28).
(12) Tighten inner hub nut with Wrench 9290 to
300 N´m (221 ft. lbs.) while spinning the wheel hub
constantly. Turn back inner nut and then tighten
until it touches the thrust washer without play. Then
tighten 1/8 turn.
(13) Install locking plate (2) (Fig. 29).
(14) Install outer hub nut and tighten with
Wrench 9290 to 250 N´m (184 ft. lbs.).
(15) Install axle shaft.
(16) Install brake caliper and support.
(17) Adjust parking brakes.
Fig. 26 OUTER HUB BEARING
1 - HUB
2 - BEARING
Fig. 27 THRUST WASHER
1 - HUB
2 - WASHER
Fig. 28 INNER HUB NUT
1 - HUB
2 - NUT
Fig. 29 LOCKING PLATE
1 - HUB
2 - PLATE
3 - 30 REAR AXLEVA

DIFFERENTIAL
REMOVAL
(1) Remove differential fill plug.
(2) Remove differential cover and drain fluid.
(3) Remove axle shafts.
(4) Mark bearing caps and housing for installation
reference.
(5) Remove differential bearing cap bolts.
(6) Mount Adapters 9317 (1) (Fig. 30) on differen-
tial housing (2).(7) Position Spreader W-129-B (2) on adapters (1)
(Fig. 31). Mount dial indicator on housing to measure
housing spread.
CAUTION: Never spread over 0.3 mm (0.011 in). If
the housing is over-spread, it could be distorted or
damaged.
(8) Remove differential (2) with bearings, cups (3)
and differential shims (Fig. 32).
(9) Mark bearings and shims for installation refer-
ence.
(10) Clean the housing cavity with flushing oil,
light engine oil or lint free cloth.
NOTE: Do not use water, steam, kerosene or gaso-
line for cleaning.
Fig. 30 SPREADER ADAPTERS
1 - ADAPTERS
2 - DIFFERENTIAL HOUSING
Fig. 31 SPREADER
1 - ADAPTERS
2 - SPREADER
Fig. 32 DIFFERENTIAL REMOVAL
1 - HOUSING
2 - DIFFERENTIAL
3 - DIFFERENTIAL BEARINGS
VAREAR AXLE 3 - 31

DISASSEMBLY
DISASSEMBLY - SINGLE REAR WHEEL
(1) Remove differential cover bolts and remove
cover (Fig. 33).
(2) Remove upper differential side gear (1) and
shim (2) (Fig. 34).(3) Remove first set of differential pinion gears (1),
spherical washers and mate shaft (2) (Fig. 35).
(4) Remove second set of differential pinion gears
(2), spherical washers and mate shaft (1) (Fig. 36).
Fig. 33 DIFFERENTIAL COVER
1 - BOLTS
2 - COVER
Fig. 34 UPPER SIDE GEAR
1 - SIDE GEAR
2 - SHIM
Fig. 35 FIRST PINION GEARS
1 - PINION GEARS
2 - MATE SHAFT
Fig. 36 SECOND PINION GEAR SET
1 - MATE SHAFT
2 - PINION GEARS
3 - 32 REAR AXLEVA

(5) Remove lower differential side gear (1) and
shim (Fig. 37).
DISASSEMBLY - DUAL REAR WHEEL
(1) Remove differential cover bolts and remove
cover (Fig. 38).(2) Remove upper differential side gear (1) and
shim (2) (Fig. 39).
(3) Remove differential cross shaft (1) with pinion
gears (2) and spherical washers (3) (Fig. 40).
Fig. 37 LOWER SIDE GEAR
1 - SIDE GEAR
2 - DIFFERENTIAL CASE
Fig. 38 DIFFERENTIAL COVER
1 - BOLTS
2 - COVER
Fig. 39 UPPER SIDE GEAR
1 - SIDE GEAR
2 - SHIM
Fig. 40 DIFFERENTIAL PINIONS
1 - CROSS SHAFT
2 - PINION GEAR
3 - WASHER
VAREAR AXLE 3 - 33

(4) Remove lower differential side gear (1) and
shim (Fig. 41).
ASSEMBLY
ASSEMBLY - SINGLE REAR WHEEL
(1) Install lower differential side gear (1) and shim
(Fig. 42).(2) Install first differential pinions gears (1) with
spherical washers and mate shaft (2) (Fig. 43).
(3) Install second pinion gears (2) with spherical
washers and mate shaft (1) (Fig. 44).
Fig. 41 LOWER SIDE GEAR
1 - SIDE GEAR
2 - DIFFERENTIAL CASE
Fig. 42 LOWER SIDE GEAR
1 - SIDE GEAR
2 - DIFFERENTIAL CASE
Fig. 43 PINION GEAR SET
1 - MATE SHAFT
2 - PINION GEARS
Fig. 44 PINION GEARS
1 - PINION GEARS
2 - MATE SHAFT
3 - 34 REAR AXLEVA

(4) Install upper differential side gear (1) and shim
(2) (Fig. 45).
(5) Install differential cover with location numbers
(1) on differential case (2) aligned (Fig. 46).(6) Install differential cover (2) bolts (1) and
tighten to 45 N´m (33 ft. lbs.) (Fig. 47).
(7) Check torque to rotate the differential gears
with Torque Tool 9744 and a torque wrench. Torque
should be 20-40 N´m (15-30 ft. lbs.).
NOTE: Shims are available in 0.05 mm (0.002 in.)
increments, in thicknesses from 1.30 - 2.00 mm
(0.051 - 0.078 in.).
Fig. 45 UPPER SIDE GEAR
1 - SIDE GEAR
2 - SHIM
Fig. 46 LOCATION NUMBERS
1 - NUMBERS
2 - CASE
Fig. 47 DIFFERENTIAL COVER
1 - BOLTS
2 - COVER
VAREAR AXLE 3 - 35