MERCEDES-BENZ SPRINTER 2006 Service Manual

ASSEMBLY - DUAL REAR WHEEL
(1) Install lower differential side gear (1) and shim
(Fig. 48).
(2) Install first differential pinions gears (2) with
spherical washers (3) and cross shaft (1) (Fig. 49).(3) Install upper differential side gear (1) and shim
(2) (Fig. 50).
(4) Install differential cover with location numbers
(1) on differential case (2) aligned (Fig. 51).
Fig. 48 LOWER SIDE GEAR
1 - SIDE GEAR
2 - DIFFERENTIAL CASE
Fig. 49 DIFFERENTIAL PINIONS
1 - CROSS SHAFT
2 - PINION GEAR
3 - WASHER
Fig. 50 UPPER SIDE GEAR
1 - SIDE GEAR
2 - SHIM
Fig. 51 LOCATION NUMBERS
1 - NUMBERS
2 - CASE
3 - 36 REAR AXLEVA

(5) Install differential cover (2) bolts (1) and tighen
to 45 N´m (33 ft. lbs.) (Fig. 52).
INSTALLATION
(1) Spread the differential housing (1).
CAUTION: Never spread over 0.3 mm (0.011 in). If
the housing is over-spread, it could be distorted or
damaged.
(2) Install differential case (2) into the housing (1)
with bearings, cups (3) and shims (Fig. 53).
(3) Loosely install differential bearing cap bolts.(4) Remove spreader (2) and adapters (1) from
housing (Fig. 54).
(5) Tighten bearing cap bolts to 70 N´m (52 ft.
lbs.).
(6) Install axle shafts.
(7) Install differential cover and tighten bolts to 65
N´m (48 ft. lbs.).
(8) Fill differential housing with lubricant.
Fig. 52 DIFFERENTIAL COVER
1 - BOLTS
2 - COVER
Fig. 53 DIFFERENTIAL INSTALLATION
1 - HOUSING
2 - DIFFERENTIAL
3 - DIFFERENTIAL BEARINGS
Fig. 54 SPREADER
1 - ADAPTERS
2 - SPREADER
VAREAR AXLE 3 - 37

BEARINGS - DIFFERENTIAL
CASE
REMOVAL
(1) Remove differential bearings with Puller
C-293-PA (1), Plug C-293-3 (2) and four Adapters
C-293-37 (3) (Fig. 55).
INSTALLATION
(1) Set differential on Plug C-293-3.
(2) Install differential (2) bearings (3) with
Installer 9523 (4) and Handle C-4171 (1) (Fig. 56).
(3) Install differential case in axle.
Fig. 55 CASE BEARING PULLER
1 - PULLER
2 - PLUG
3- ADAPTERS
Fig. 56 DIFFERENTIAL BEARINGS
1 - HANDLE
2 - DIFFERENTIAL
3 - BEARING
4 - INSTALLER
3 - 38 REAR AXLEVA

SEAL - PINION
REMOVAL
(1) Remove wheels.
(2) Push back brake pads and release hand brake.
NOTE: If it is not possible to spin rear axle shafts
manually, detach rear brake cables.
(3) Drain rear axle oil.
NOTE: On dual rear wheel axle remove axle shafts.
(4) Remove propeller shaft.
(5) Spin pinion flange by hand and check axial
play of bearing.
CAUTION: There must not be any thrust bearing
play. If play excess or there are particles (shavings)
in the drained oil, replace gear assembly.
(6) Measure and record torque to rotate the pinion.
(7) Mark pinion position to pinion flange (1) (Fig.
57).
(8) Unlock collared nut.
(9) Hold pinion flange (1) with Flange Wrench
C-3281 and remove nut.(10) Remove pinion flange (1) from pinion shaft
with Flange Puller 8992 (2) (Fig. 58).
(11) Check sealing surfaces of joint flange for score
marks and replace joint flange if necessary.
(12) Remove pinion seal/seals (1) (Fig. 59).
Fig. 57 COLLARED NUT
1 - PINION FLANGE
2 - COLLARED NUT
Fig. 58 FLANGE PULLER
1 - FLANGE PULLER
2 - PINION FLANGE
Fig. 59 PINION SEALS
1 - SEALS
2 - AXLE
VAREAR AXLE 3 - 39

INSTALLATION
(1) Pack space between dust lip and sealing lip on
seal ring with multi-purpose grease.
(2) On seals without rubberized external surface,
coat outer circumference with sealant.
CAUTION: Do not coat partially rubberized seals
with sealant.
(3) Drivenewpinion seal/seals into rear axle
housing as far as the stop using Installer 9276 (2)
(Fig. 60).
(4) Fit coupling flange on drive pinion shaft.
NOTE: The groove in the drive pinion and the
groove in the joint flange must be in alignment.
(5) Hold pinion flange with Flange Wrench C-3281.
(6) Tighten collar nut to 100 N´m. (74 ft. lbs.).
(7) Using a dial indicator check free play at pinion
flange.NOTE: Should bearing not be free of play, tighten in
increases of 10 N´m. (88 in. lbs.) to maximun of 130
N´m. (95 ft. lbs.). If bearing is not free from play at
130 N´m. (95 ft. lbs.) collapsible spacer must be
replaced.
(8) Identify the position of the pinion to the nut
twevle points and mark pinion and nut.
(9) Turn nut pinion nut 30É (one twelve point).
Them rotate pinion thirty times.
(10) Measure torque to rotate. The torque to rotate
must be 0.1-0.2 N´m (0.9-1.7 in. lbs.) higher then
recorded torque.
NOTE: If value is below or above collapsible spacer
must be replaced.
(11) Cut the collar of the collared nut (Fig. 61).
(12) Bend collar nut (1) so it touches the wall of
the slot in the pinion shaft (Fig. 62).
Fig. 60 PINION SEAL INSTALLER
1 - AXLE
2 - INSTALLER
Fig. 61 COLLARED NUT
Fig. 62 BEND COLLAR OF NUT
1 - COLLARED NUT
2 - DRIFT
3 - 40 REAR AXLEVA

(13) Connect propeller shaft to pinion flange.
NOTE: On dual rear wheel axle install axle shafts.
(14) Pour in oil up to bottom edge of oil filler hole
(1) (Fig. 63).
(15) Screw in oil filler plug (1) and tighten to 100
N´m (74 ft. lbs.).
(16) Install wheels at rear axle.
(17) Operate brake pedal several times until brake
pads contact brake discs (brake pressure built up).
(18) Attach rear brake cables if removed and
adjust parking brake.
GEAR - PINION / RING
REMOVAL
NOTE: The ring and pinion gears are serviced in a
matched set. Never replace one gear without replac-
ing the other gear.
(1) Remove differential from housing.
(2) Place differential case in a vise with soft metal
jaw.
(3) Remove ring gear bolts from the differential
case.
(4) Drive ring gear off the differential case with a
dead-blow hammer (Fig. 64).(5) Unlock collared nut.
(6) Hold pinion flange with Flange Wrench C-3281
and remove nut.
(7) Remove pinion flange from pinion shaft with
Puller 8892 and Wrench C-3281 (Fig. 65).
(8) Remove pinion gear from housing with a dead-
blow hammer.
(9) Remove pinion shaft seal with a seal pick.
(10) Remove front pinion bearing.
(11) Remove front pinion bearing cup with
Remover D-103 and Handle C-4171.
(12) Remove rear pinion bearing cup with Remover
9084 and Handle C-4171.
(13) Remove pinion depth shim from rear pinion
bearing cup bore.
(14) Remove collapsible spacer (Fig. 66).
Fig. 63 FILL PLUG
1 - FILL PLUG
2 - DRAIN PLUG
Fig. 64 RING GEAR
1 - CASE
2 - RING GEAR
3 - DEAD-BLOW HAMMER
Fig. 65 FLANGE PULLER
1 - FLANGE PULLER
2 - PINION FLANGE
VAREAR AXLE 3 - 41

(15) Remove spacer from pinion shaft (Fig. 67).
(16) Remove rear bearing from pinion shaft with
Puller/Press C-293-PA and Adapters C-293-47 (Fig.
68).
INSTALLATION
(1) Apply Mopar Door Ease or equivalent lubricant
to outside surface of bearing cups.
(2) Install pinion depth shim in rear pinion bear-
ing cup bore.
(3) Install rear pinion bearing cup with Installer
C-4310 and Driver Handle C-4171.
(4) Install front pinion bearing cup with Installer
8617 and Handle C-4171.
(5) Install rear bearing on pinion with Installer
MB-998805 and a press (Fig. 69).
Fig. 66 COLLAPSIBLE SPACER
1 - COLLAPSIBLE SPACER
2 - SPACER
Fig. 67 SPACER
1 - SPACER
2 - PINION SHAFT
Fig. 68 Rear Bearing Removal
1 - PULLER
2 - VISE
3 - ADAPTERS
4 - DRIVE PINION GEAR SHAFT
3 - 42 REAR AXLEVA

(6) Install pinion spacer on pinion shaft (Fig.
70).
(7) Installnewcollapsible preload spacer on pin-
ion shaft (Fig. 71) and install pinion gear into the
housing.(8) Install front pinion bearing into housing with
Installer 9548.
(9) Apply a light coating of gear lubricant on the
lip of pinion seal and install seal with Installer 9276
(Fig. 72).
(10) Hold pinion flange with Flange Wrench
C-3281.
(11) Screw on thenewcollared nut.
(12) Tighten collar nut carefully to a torque to
rotate of 2.5-3 N´m (22-27 in. lbs.).
(13) Cut the collar of the tightened collared nut
(Fig. 73).
Fig. 69 REAR BEARING INSTALLATION
1 - PRESS
2 - INSTALLER
3 - DRIVE PINION GEAR
4 - REAR PINION BEARING
Fig. 70 SPACER
1 - SPACER
2 - PINION SHAFT
Fig. 71 COLLAPSIBLE SPACER
1 - COLLAPSIBLE SPACER
2 - SPACER
Fig. 72 PINION SEAL INSTALLER
1 - AXLE
2 - INSTALLER
VAREAR AXLE 3 - 43

(14) Bend collar so it touches the wall of the slot
in the pinion shaft (Fig. 74).
(15) Invert differential case and start two ring
gear bolts. This will provide case-to-ring gear bolt
hole alignment.
(16) Invert differential case in the vise and install
new ring gear bolts and alternately tighten to 180
N.m (133 ft. lbs.) (Fig. 75)
CAUTION: Do not reuse ring gear bolts, the bolts
can fracture causing extensive damage. Failure to
heed caution may result in damage.(17) Install differential in axle housing and verify
gear mesh and contact pattern.
Fig. 73 COLLARED NUT
Fig. 74 BEND COLLAR OF NUT
1 - COLLARED NUT
2 - DRIFT
Fig. 75 RING GEAR
1 - TORQUE WRENCH
2 - RING GEAR BOLT
3 - RING GEAR
4 - CASE
3 - 44 REAR AXLEVA

BRAKES
TABLE OF CONTENTS
page page
BRAKES - BASE........................... 1BRAKES - ABS........................... 30
BRAKES - BASE
TABLE OF CONTENTS
page page
BRAKES - BASE
DIAGNOSIS AND TESTING - BASE BRAKE
SYSTEM.............................2
STANDARD PROCEDURE
STANDARD PROCEDURE - MANUAL
BLEEDING............................4
STANDARD PROCEDURE - PRESSURE
BLEEDING............................5
HYDRAULIC/MECHANICAL
SPECIFICATIONS
SPECIFICATIONS - TORQUE CHART.......5
BASE BRAKE.........................6
SPECIAL TOOLS
BRAKES.............................7
BRAKE LINES
STANDARD PROCEDURE
STANDARD PROCEDURE - ISO FLARING . . . 8
STANDARD PROCEDURE - DOUBLE
INVERTED FLARING....................8
BRAKE PADS/SHOES
REMOVAL
REMOVAL - FRONT (SRW)...............8
REMOVAL - FRONT (DRW)...............9
REMOVAL - REAR (16º WHEELS) (SRW)....9
REMOVAL - REAR (15º WHEELS) (SRW) . . . 10
REMOVAL - REAR (DRW)...............10
INSTALLATION
INSTALLATION - FRONT (SRW)...........11
INSTALLATION - FRONT (DRW)..........11
INSTALLATION - REAR (16º WHEELS)
(SRW) ..............................11
INSTALLATION - REAR (16º WHEELS)
(SRW) ..............................11
INSTALLATION - REAR (DRW)...........11
DISC BRAKE CALIPERS
REMOVAL
REMOVAL - FRONT (SRW)..............11
REMOVAL - FRONT (DRW)..............12
REMOVAL - REAR (SRW)...............12
REMOVAL - REAR (DRW)...............13INSTALLATION
INSTALLATION - FRONT (SRW)..........13
INSTALLATION - FRONT (DRW)..........13
INSTALLATION - REAR (SRW)...........14
INSTALLATION - REAR (DRW)...........14
DISC BRAKE CALIPER ADAPTER
REMOVAL
REMOVAL - FRONT....................14
REMOVAL - REAR.....................14
INSTALLATION
INSTALLATION - FRONT................14
INSTALLATION - REAR.................14
FLUID
DIAGNOSIS AND TESTING - BRAKE FLUID
CONTAMINATION.....................15
STANDARD PROCEDURE - BRAKE FLUID
LEVEL..............................15
SPECIFICATIONS
BRAKE FLUID........................15
FLUID RESERVOIR
REMOVAL.............................15
INSTALLATION.........................15
ALB LEVER
REMOVAL.............................16
INSTALLATION.........................16
ALB CONTROLLER
REMOVAL.............................16
INSTALLATION.........................16
ADJUSTMENTS
ADJUSTMENT........................16
MASTER CYLINDER
DIAGNOSIS AND TESTING - MASTER
CYLINDER/POWER BOOSTER...........17
STANDARD PROCEDURE - MASTER
CYLINDER BLEEDING..................18
REMOVAL.............................18
INSTALLATION.........................19
PEDAL
REMOVAL.............................19
INSTALLATION.........................19
VABRAKES 5 - 1