MERCEDES-BENZ SPRINTER 2005 Service Workshop Manual

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.
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. Listenfor 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 and drain oil (Fig. 1).
(3) Install oil drain plug and tighten to N´m 100
(74 ft. lbs.).
(4) Remove oil fill plug and fill housing up to bot-
tom edge of oil fill hole (Fig. 1).
(5) Install oil fill plug and tighten to N´m 100 (74
ft. lbs.).
REMOVAL
(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 from adjuster.
(9) Remove brake calipers with adapters and lines.
Fig. 1 FILL PLUG
1 - FILL PLUG
2 - DRAIN PLUG
VAREAR AXLE 3 - 11
REAR AXLE (Continued)

(10) Remove stablizer bar from axle brackets.
(11) Remove shock absorber bolts from rear axle.
(12) Remove ALB lever from rear axle bracket.
(13) Pull off hold-down clips and remove brake
hoses.
(14) Pull vent line of rear axle out of frame.
(15) Remove propeller shaft.
(16) Remove U-brackets and plates (Fig. 2) and
(Fig. 3).
(17) Remove axle from the vehicle.
INSTALLATION
(1) Raise axle into position.
(2) Install plates and U-brackets 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.
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 - 12 REAR AXLEVA
REAR AXLE (Continued)

(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.
SPECIFICATIONS
AXLE SPECIFICATIONS
DESCRIPTION SPECIFICATION
Axle Ratio 3.73, 4.11
Ring Gear Diameter 216 mm (8.5 in.)
Fig. 3 DUAL REAR WHEEL AXLE
1 - SPRING 11 - WEAR INDICATOR CONNECTOR
2 - SPRING SHACKLE 12 - BRAKE HOSE
3 - PLATE 13 - LUG NUT
4 - COLLAR NUT 14 - NUT
5 - BRAKE CABLE 15 - WASHER
6 - REAR AXLE 16 - BOLT
7 - ALB LEVER 17 - SHOCK ABSORBER
8 - NUT 18 - PROPELLER SHAFT
9 - BOLT 19 - BOLT
10 - WEAR INDICATOR CABLE 20 - ABS SENSOR
21 - SENSOR BUSHING
VAREAR AXLE 3 - 13
REAR AXLE (Continued)

TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Drain Plug 100 74 -
Fill Plug 100 74 -
Differential Cover Bolts 65 48 -
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.
SPECIAL TOOLS
SPECIAL TOOL CROSS-REFERENCE CHART
MB TOOL #MILLER TOOL
#DESCRIPTION
460-589-15-15-
009276 INSTALLER
741 589 01 15
009278 INSTALLER
741 589 00 35
009277 PLATE
460 589 01 07
009279 WRENCH
N/A 8992FLANGE
PULLER
309 589 01 07
009290 WRENCH
389 589 02 15
009291 INSTALLER
N/A C-3281 WRENCH
INSTALLER 9276
INSTALLER 9278
PLATE 9277
3 - 14 REAR AXLEVA
REAR AXLE (Continued)

AXLE SHAFTS
REMOVAL
(1) Remove wheels.
(2) Detach front brake cable.
(3) Pull ABS sensor together with clamp bushing
out of bearing cap (Fig. 4).
(4) Remove brake disk at rear axle. Attach brake
caliper with lines connected in wheel house.
(5) Remove brake shoes of parking brake.
(6) Remove brake control cable lock.
(7) Remove bearing cap bolts and pull axle shaft
out of axle tube (Fig. 4).
(8) Remove seal/gasket.
INSTALLATION
(1) Install sealing ring.
(2) Install rear axle shaft in the axle tube (Fig. 5).
(3) Installnewbearing cap bolts and tighten to 72
N´m (53 ft. lbs.) (Fig. 6).
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.
WRENCH 9279
FLANGE PULLER 8992
WRENCH 9290
INSTALLER 9291
WRENCH C-3281
VAREAR AXLE 3 - 15
REAR AXLE (Continued)

Fig. 4 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
Fig. 5 AXLE SHAFT AND TUBE
1 - AXLE SHAFT FLANGE
2 - AXLE TUBE
3 - AXLE BEARINGS
4 - DUST SHIELD
Fig. 6 BEARING CAP BOLTS
1 - BEARING CAP BOLTS
2 - BEARING CAP
3 - AXLE SHAFT FLANGE
3 - 16 REAR AXLEVA
AXLE SHAFTS (Continued)

AXLE BEARINGS/SEALS
REMOVAL
(1) Remove rear axle shaft.
(2) With a punch and hammer straighten locking
ring (Fig. 7).
(3) Loosen bearing nut with Wrench 9279 (Fig. 8).
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. To dismantling insert two wheel mounting
bolts into the axle shaft and clamp in a vise.(4) Remove bearing nut and locking ring from axle
shaft (Fig. 9).
(5) Push Plate 9277 between bearing cover and
rear axle shaft (Fig. 10).
(6) Place axle shaft with plate in a press.
(7) Press axle shaft through the bearing cover and
tapered roller bearings (Fig. 11).
(8) Remove tapered roller bearing, sealing ring,
dust shield and bearing cap from axle shaft (Fig. 12).
(9) Drive shaft seal out of bearing cover with a
hammer and drift.
INSTALLATION
(1) Clean sealing surface of bearing cap.
(2) Drive axle shaft seal into bearing cover using
Installer 9278 (Fig. 13).
Fig. 7 LOCKING RING
1 - BEARING NUT
2 - PUNCH
3 - LOCKING RING
4 - BEARING
Fig. 8 BEARING NUT WRENCH
1 - AXLE SHAFT
2 - BEARING NUT
3 - WRENCH
4 - BEARING
Fig. 9 BEARING NUT AND LOCKING RING
1 - BEARING NUT
2 - LOCKING RING
Fig. 10 AXLE BEARING REMOVAL TOOL
1 - AXLE SHAFT
2 - PLATE
VAREAR AXLE 3 - 17

NOTE: Install flush to a max. 3 mm (0.12 in.) deep
inside the bearing cover.
(3) Check roller bearing, replace according to con-
dition.
NOTE: Thoroughly grease roller bearings prior to
installation.
(4) Install bearing cover with axle shaft seal,new
gasket and dust shield on the axle shaft.
(5) Install tapered roller bearings and race on the
axle shaft (Fig. 14).
(6) Installnewlocking ring on axle shaft.NOTE: The flat side of the locking ring must point
towards the nut (Fig. 15). The locking ring is fitted
to ensure that the pressing is done over the inner
bearing 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 through the hole in Plate 9277
and position the assembly in a press (Fig. 16).
(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.
(9) Screw on bearing nut and tighten nut with
Wrench 9279 to 500 N´m (369 ft. lbs.).
Fig. 11 PRESSING BEARING
1 - AXLE SHAFT
2 - BEARING
3 - PLATE
Fig. 12 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
Fig. 13 SEAL INSTALLER
1 - INSTALLER
2 - BEARING COVER
Fig. 14 BEARINGS AND RACE
1 - BEARINGS
2 - RACE
3 - 18 REAR AXLEVA
AXLE BEARINGS/SEALS (Continued)

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 with a hammer and punch
at both grooves in the bearing nut (Fig. 17).
NOTE: The grooved nut must be locked in both
directions of rotation.
(11) Install sealing ring onto roller bearing race
(Fig. 17).
(12) Install rear axle shaft.
AXLE SHAFTS - DUAL REAR
WHEELS
REMOVAL
(1) Remove wheels
(2) Remove axle shaft hub nuts (Fig. 18).
(3) Pull out axle shaft.
INSTALLATION
(1) Coat axle shaft flange with Hylomar SQ 32 M
sealant.
Fig. 15 BEARING AND SHAFT
1 - LOCKING RING
2 - AXLE SHAFT
3 - BEARING
4 - DUST SHIELD
Fig. 16 PRESSING AXLE SHAFT
1 - PRESS
2 - AXLE SHAFT
3 - PLATE
Fig. 17 LOCKING RING
1 - BEARING NUT
2 - BEARING
3 - LOCKING RING
4 - SEALING RING
Fig. 18 AXLE SHAFT
1 - WHEEL HUB
2 - AXLE SHAFT
3 - AXLE NUT
VAREAR AXLE 3 - 19
AXLE BEARINGS/SEALS (Continued)

(2) Slide axle shaft into axle tube.
(3) Install axle shaft hub nuts and tighten to N´m
65 (48 ft. lbs.).
(4) Install wheels.
AXLE HUB BEARINGS/SEALS
REMOVAL
(1) Remove brake caliper with support.
(2) Remove axle shaft.
(3) Back-off parking brakes.
(4) Remove outer hub nut with Wrench 9290 (Fig.
19).
(5) Remove locking plate, inner hub nut and thrust
washer (Fig. 19).
(6) Pull hub off axle tube.
(7) Pry out ABS sensor and remove seal from hub
(Fig. 20).
(8) Remove hub bearings from hub (Fig. 21).
(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 with
Hylomar SQ 32 M sealant.CAUTION: Do not coat seals rubberized sealing sur-
faces with sealant.
(5) Install seal into hub with an appropriate
installer.
NOTE: Sealing ring should be flush with wheel hub
or max. 3mm (0.12 in.) deep.
(6) Coat contact surface of ABS sensor ring with
Hylomar SQ 32 M sealant.
Fig. 19 HUB NUTS
1 - NUTS
2 - LOCKING PLATE
3 - THRUST WASHER
Fig. 20 SENSOR RING & OIL SEAL
1 - ABS SENSOR RING
2 - SEAL
Fig. 21 AXLE HUB BEARINGS
1 - REAR BEARING
2 - HUB
3 - FRONT BEARING
4 - ROTOR
3 - 20 REAR AXLEVA
AXLE SHAFTS - DUAL REAR WHEELS (Continued)