wheel alignment MERCEDES-BENZ SPRINTER 2005 Service Repair Manual

SUSPENSION
TABLE OF CONTENTS
page page
FRONT.................................1
REAR.................................11WHEEL ALIGNMENT.....................17
FRONT
TABLE OF CONTENTS
page page
FRONT
SPECIFICATIONS - TORQUE CHART.........2
SPECIAL TOOLS
FRONT SUSPENSION...................2
BUSHINGS
REMOVAL.............................3
INSTALLATION..........................3
HUB / BEARING
DIAGNOSIS AND TESTING -...............4
REMOVAL.............................4
INSTALLATION..........................5
KNUCKLE
REMOVAL.............................5
INSTALLATION..........................5
LOWER BALL JOINT
REMOVAL.............................6
INSTALLATION..........................6
LOWER CONTROL ARM
REMOVAL.............................6
INSTALLATION..........................6SPRING
REMOVAL.............................7
INSTALLATION..........................8
SPRING CLAMP PLATES
REMOVAL.............................8
INSTALLATION..........................8
SPRING STOP PLATES
REMOVAL.............................9
INSTALLATION..........................9
STABILIZER BAR
DESCRIPTION..........................9
OPERATION............................9
REMOVAL.............................9
INSTALLATION..........................9
STABILIZER LINK
REMOVAL.............................9
INSTALLATION..........................9
STRUT
REMOVAL.............................10
INSTALLATION.........................10
VASUSPENSION 2 - 1

(2) Install the lower ball joint nut (Fig. 6). Tighten
to 280 N´m (206 ft. lbs.)
(3) Install the strut to the steering knuckle (Fig.
6). Tighten to 185 N´m (136 ft. lbs.).
(4) Install the outer tie rod end to the steering
knuckle (Fig. 6) and tighten the nut to 130 N´m (96
ft. lbs.).
(5) Install the ABS sensor by pushing the sensor
all the way into the knuckle and the sensor will self
adjust when the wheel is turned.
(6) Install the hub/bearing (Refer to 2 - SUSPEN-
SION/FRONT/HUB / BEARING - INSTALLATION).
(7) Install the disc brake caliper adapter with the
brake caliper (Refer to 5 - BRAKES/HYDRAULIC/
MECHANICAL/DISC BRAKE CALIPER ADAPTER -
INSTALLATION).
(8) Install the front wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - INSTALLATION).
(9) Lower the vehicle.
(10) Check and set toe if necessary (Refer to 2 -
SUSPENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE).
LOWER BALL JOINT
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the front tire and wheel assembly.
(3) Remove the front strut (Refer to 2 - SUSPEN-
SION/FRONT/STRUT - REMOVAL).
(4) Remove the steering knuckle (Refer to 2 - SUS-
PENSION/FRONT/KNUCKLE - REMOVAL).
(5) Remove the lower ball joint using special tool
9294-1 (Driver) with 9294-2 (Reciever) and C-4212±F.
(Fig. 7).
INSTALLATION
(1) Install the ball joint into the lower control arm
using special tool 9294-3 (Installer ring) inserted in
9294-2 (Reciever) and C-4212±F (Fig. 7).
(2) Install the front strut (Refer to 2 - SUSPEN-
SION/FRONT/STRUT - INSTALLATION).
(3) Install the steering knuckle (Refer to 2 - SUS-
PENSION/FRONT/KNUCKLE - INSTALLATION).
(4) Install the tire and wheel assembly (Refer to 22
- TIRES/WHEELS/WHEELS - INSTALLATION).
(5) Lower the vehicle.
(6) Check the front wheel alignment (Refer to 2 -
SUSPENSION/WHEEL ALIGNMENT - SPECIFICA-
TIONS).
LOWER CONTROL ARM
REMOVAL
(1) Insert spring blocks special tool 9288 between
the spring and the spring clamp plates, While the
vehicles wheels are on the ground.
(2) Raise and support the vehicle.
(3) Remove the front wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - REMOVAL).
(4) Remove the disc brake caliper adapter (Refer to
5 - BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - REMOVAL).Hang
the caliper. Do not allow brake hose to support
the caliper weight.
(5) Remove the retaining nut holding the tie rod to
the steering knuckle (Fig. 8).
(6) Seperate the tie rod off the steering knuckle
(Fig. 8) using special tool C-3894±A.
NOTE: In order to remove tension from the strut,
Raise the lower control arm approximately 10 mm
with a jack.
(7) Remove the strut bolts from the steering
knuckle (Fig. 8).
(8) Remove the stop plate bolts and rotate the
plate upwards with the stabilizer link attached (Fig.
8).
(9) Lower the lower control arm.
(10) Remove the lower ball joint nut from the
steering knuckle (Fig. 8).
(11) Separate the lower ball joint from the knuckle
using special tool 9282.
(12) Remove the lower control arm nuts and bolts
from the frame (Fig. 8).
(13) Remove the lower control arm.
INSTALLATION
(1) Install the lower control arm to the frame.
Hand tighten the nuts and bolts.
Fig. 7 LOWER BALL JOINT
1 - LOWER CONTROL ARM
2 - LOWER BALL JOINT
2 - 6 FRONTVA
KNUCKLE (Continued)

(16) Lower the jack and remove the transverse leaf
spring towards the side.
INSTALLATION
NOTE: To avoid damaging the transverse leaf
spring, cushion the pad on the jack accordingly.
NOTE: Hand tighten all bolts until vehicle is on the
ground, unless the bushings may become distorted.
NOTE: The height blocks between the engine cradle
and the spring are color coded, Make sure not to
mix the blocks per sides. The blocks are different in
sizes to accommodate the weight of the vehicle and
driver in order for the vehicle to sit level.
(1) Install the transverse leaf spring in the center
with a jack with all the rubber mounts attached.
(2) Install the lower control arm to the frame (Fig.
9).
(3) Install the knuckle on the lower ball joint.(4) Raise the lower control arm approximately 10
mm with a jack.
(5) Install both stop plate bolts to the lower control
arm
(6) Install the strut bolts to the steering knuckle.
(7) Reinstall the tie rod to the steering knuckle
(Fig. 9). Tighten to 150 N´m (110 ft. lbs.).
(8) Install the ABS sensor all the way into the
steering knuckle, the sensor will adjust automatically
when the vehicle is moved (Fig. 9).
(9) Install the disc brake caliper adapter (Fig. 9).
Tighten to 170 N´m (125 ft. lbs.).
(10) Install the front wheels.
(11) Lower the vehicle.
(12) Install the spring clamp plates (Fig. 9).
Tighten (M-10 bolts) to 65 N´m (48 ft. lbs.) (M-12
bolts) to 130 N´m (96 ft. lbs.).
(13) Roll the vehicle approximately 1 mm forwards
and the backwards, and rock firmly.
(14) Tighten the nuts on the lower control arm to
the frame to 150 N´m (110 ft. lbs.).
(15) Apply brake to actuate brake pressure.
SPRING CLAMP PLATES
REMOVAL
(1) Raise and support the vehicle.
(2) Install a jack under the lower ball joint and
lower the weight of the vehicle enough to allow a
wrench between the lower control arm and the
bracket tighten the nut.
(3) Remove the front and rear bolts to the spring
clamp plates.
(4) Remove the four inner retaining bolts and
nuts.
(5) Remove the spring clamp plate and rubber
block.
(6) Remove the shear bushings from the front and
rear bolts.
INSTALLATION
(1) Install a jack under the lower ball joint and
lower the weight of the vehicle enough to allow a
wrench between the lower control arm and the
bracket tighten the nut.
(2) Fit one spring clamp plate together with the
lower spring rubber block.
(3) Install the bolt with the shear bushing on the
rear mounting,Do not tighten yet.
(4) Install the four retaining bolts for the spring
clamp plate. Tighten to 65 N´m (48 ft.lbs.).
(5) Align the holes for the front clamp plate joint
using a suitable drift (shear bushing not installed).
(6) Remove the alignment drift.
Fig. 9 FRONT SPRING
1 - NUT
2 - STRUT
3 - STOP PLATE
4 - STOP PLATE BOLT
5 - CALIPER ADAPTER BOLT
6 - DISC BRAKE CALIPER
7 - OUTER TIE ROD END NUT
8 - ABS SENSOR
9 - SPEED SENSOR
10 - LOWER CONTROL ARM RETAINING NUTS
11 - OUTER TIE ROD END
12 - RUBBER SPRING MOUNT
13 - SHEAR BUSHING
14 - SPRING CLAMP PLATE BOLT
15 - SPRING CLAMP PLATE
16 - LOWER RUBBER SPRING MOUNT
17 - SPRING
18 - STRUT BOLTS
19 - LOWER CONTROL ARM BOLTS
2 - 8 FRONTVA
SPRING (Continued)

WHEEL ALIGNMENT
TABLE OF CONTENTS
page page
WHEEL ALIGNMENT
DESCRIPTION.........................17
DIAGNOSIS AND TESTING - PRE-ALIGNMENT
INSPECTION.........................17STANDARD PROCEDURE - TOE
ADJUSTMENT........................19
SPECIFICATIONS.......................19
WHEEL ALIGNMENT
DESCRIPTION
NOTE: Camber and Caster are not adjustable on
this vehicle. (TOE ONLY).
NOTE: Suspension components with rubber/ure-
thane bushings should be tightened with the vehi-
cle at normal ride height. It is important to have the
springs supporting the weight of the vehicle when
the fasteners are torqued. If springs are not at their
normal ride position, vehicle ride comfort could be
affected and premature bushing wear may occur.
Wheel alignment involves the correct positioning of
the wheels in relation to the vehicle. The positioning
is accomplished through suspension and steering
linkage adjustments. An alignment is considered
essential for efficient steering, good directional stabil-
ity and to minimize tire wear. The most important
measurements of an alignment are caster, camber
and toe (Fig. 1).
CAUTION: Never attempt to modify suspension or
steering components by heating or bending.
DIAGNOSIS AND TESTING - PRE-ALIGNMENT
INSPECTION
Before starting wheel alignment, the following
inspection and necessary corrections must be com-
pleted. Refer to Suspension and Steering System
Diagnosis Chart below for additional information.(1) Inspect tires for size, air pressure and tread
wear.
(2) Inspect front wheel bearings for wear.
(3) Inspect front wheels for excessive radial or lat-
eral runout and balance.
(4) Inspect ball studs, linkage pivot points and
steering gear for looseness, roughness or binding.
(5) Inspect suspension components for wear and
noise.
(6) Road test the vehicle.
Fig. 1 Wheel Alignment Measurements
1 - FRONT OF VEHICLE
2 - STEERING AXIS INCLINATION
3 - PIVOT POINT
4 - TOE-IN
VAWHEEL ALIGNMENT 2 - 17

SUSPENSION AND STEERING SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
FRONT END NOISE 1. Loose or worn wheel bearing. 1. Replace wheel bearing.
2. Loose or worn steering or
suspension components.2. Tighten or replace components as
necessary.
3. Loose or worn steering or
suspension components.3. Tighten or replace components as
necessary.
EXCESSIVE PLAY IN
STEERING1. Loose or worn wheel bearing. 1. Replace wheel bearing.
2. Loose or worn steering or
suspension components.2. Tighten or replace components as
necessary.
3. Loose or worn steering gear. 3. Replace steering gear.
FRONT WHEELS SHIMMY 1. Loose or worn wheel bearing. 1. Replace wheel bearing.
2. Loose or worn steering or
suspension components.2. Tighten or replace components as
necessary.
3. Tires worn or out of balance. 3. Replace or balance tires.
4. Alignment. 4. Align vehicle to specifications.
VEHICLE INSTABILITY 1. Loose or worn wheel bearing. 1. Replace wheel bearing.
2. Loose or worn steering or
suspension components.2. Tighten or replace components as
necessary.
3. Tire pressure. 3. Adjust tire pressure.
4. Alignment. 4. Align vehicle to specifications.
EXCESSIVE STEERING
EFFORT1. Loose or worn steering gear. 1. Replace steering gear.
2. Column coupler binding. 2. Replace coupler.
3. Tire pressure. 3. Adjust tire pressure.
4. Alignment. 4. Align vehicle to specifications.
VEHICLE PULLS TO ONE
SIDE1. Tire pressure. 1. Adjust tire pressure.
2. Tire. 2. Criss-Cross Front Tires.
3. Alignment. 3. Align vehicle to specifications.
4. Loose or worn steering or
suspension components.4. Tighten or replace components as
necessary.
5. Radial tire lead. 5. Rotate or replace tire as necessary.
6. Brake pull. 6. Repair brake as necessary.
7. Weak or broken spring. 7. Replace spring.
2 - 18 WHEEL ALIGNMENTVA
WHEEL ALIGNMENT (Continued)

STANDARD PROCEDURE - TOE ADJUSTMENT
CAMBER AND CASTER ARE NOT ADJUSTABLE
(TOE ONLY)..
The wheel toe position adjustment is the final
adjustment.
(1) Start the engine and turn wheels both ways
before straightening the wheels. Secure the steering
wheel with the front wheels in the straight-ahead
position.
(2) Loosen the tie rod jam nuts.
NOTE: Each front wheel should be adjusted for
one-half of the total toe position specification. This
will ensure the steering wheel will be centered
when the wheels are positioned straight-ahead.
(3) Adjust the wheel toe position by turning the
inner tie rod as necessary.
(4) Tighten the tie rod jam nut to 50 N´m (37 ft.
lbs.).
(5) Verify the specifications
(6) Turn off engine.
SPECIFICATIONS
FRONT SPECIFICATIONS
DESCRIPTION FRONT SPECIFICATION
Toe-In  .16É
DESCRIPTION FRONT SPECIFICATION
Camber  .75É
Camber
Left to Right Difference
Max1.33É
Caster  .5É
Steering Knuckle
Inclination .5É
Steering Knuckle
Inclination
Left to Right Difference
Max1É
REAR SPECIFICATIONS
DESCRIPTION REAR SPECIFICATION
Toe-In
Max0É ( .25É)
Camber
Max0É (-.66É/+.33É)
Inclination of Rear
Wheels (Individual Wheel
Toe)= Maximum
Inclination of Rear Axle
Max0É ( .25É)
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Outer Tie Rod End Jam
Nut50 37 Ð
VAWHEEL ALIGNMENT 2 - 19
WHEEL ALIGNMENT (Continued)

DRIVELINE VIBRATION
Drive Condition Possible Cause Correction
Propeller Shaft Noise 1) Undercoating or other foreign
material on shaft.1) Clean exterior of shaft and wash
with solvent.
2) Loose U-joint clamp screws. 2) Install new clamps and screws
and tighten to proper torque.
3) Loose or bent U-joint yoke or
excessive runout.3) Install new yoke.
4) Incorrect driveline angularity. 4) Measure and correct driveline
angles.
5) Rear spring center bolt not in
seat.5) Loosen spring u-bolts and seat
center bolt.
6) Worn U-joint bearings. 6) Install new U-joint.
7) Propeller shaft damaged or out
of balance.7) Installl new propeller shaft.
8) Broken rear spring. 8) Install new rear spring.
9) Excessive runout or unbalanced
condition.9) Re-index propeller shaft, test,
and evaluate.
10) Excessive drive pinion gear
shaft runout.10) Re-index propeller shaft and
evaluate.
11) Excessive axle yoke deflection. 11) Inspect and replace yoke if
necessary.
12) Excessive transfer case runout. 12) Inspect and repair as necessary.
Universal Joint Noise 1) Loose U-joint clamp screws. 1) Install new clamps and screws
and tighten to proper torque.
2) Lack of lubrication. 2) Replace as U-joints as
necessary.
PROPELLER SHAFT BALANCE
NOTE: Removing and indexing the propeller shaft
180É relative to the yoke may eliminate some vibra-
tions.
If propeller shaft is suspected of being out of bal-
ance, verify with the following procedure:
(1) Place vehicle in netrual.
(2) Raise and support the vehicle by the axles as
level as possible.
(3) Clean all foreign material from propeller shaft
and universal joints.
(4) Inspect propeller shaft for missing balance
weights, broken welds, and bent areas.
NOTE: If propeller shaft is bent, it must be replaced.
(5) Inspect universal joints for wear, properly
installed and correct alignment with the shaft.
(6) Check universal joint clamp screws torque.
(7) Remove wheels and tires. Install wheel lug
nuts to retain the brake drums/rotors.(8) Mark and number propeller shaft six inches
from the pinion yoke end at four positions 90É apart.
(9) Run and accelerate the vehicle until vibration
occurs. Note intensity and speed the vibration
occurred. Stop the engine.
(10) Install a screw clamp at position 1 (Fig. 1).
(11) Start engine and re-check for vibration. If lit-
tle or no change in vibration is evident, move clamp
to the next positions and repeat vibration test.
NOTE: If there is no difference in vibration at the
other positions, the vibration may not be propeller
shaft.
(12) If vibration decreased, install a second clamp
(Fig. 2) and repeat vibration test.
(13) If additional clamp causes additional vibra-
tion, separate clamps 1/2 inch above and below the
mark. Repeat the vibration test (Fig. 3).
(14) Increase distance between clamps and repeat
test until vibration is at the lowest level. Bend the
slack end of the clamps so the screws will not loosen.
3 - 2 PROPELLER SHAFTVA
PROPELLER SHAFT (Continued)

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
(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.).
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
3 - 6 PROPELLER SHAFTVA
PROPELLER SHAFT (Continued)

PINION SEAL
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.
(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) Mark installation position of collared nut (Fig.
26) with respect to drive pinion.
(7) Unlock collared nut.
(8) Hold pinion flange with Flange Wrench C-3281
and remove nut.
(9) Remove pinion flange from pinion shaft with
Flange Puller 8992 (Fig. 27).
(10) Check sealing surfaces of joint flange for score
marks and replace joint flange if necessary.
(11) Remove both pinion radial seals (Fig. 28).
INSTALLATION
(1) Pack space between dust lip and sealing lip on
radial seal ring with multi-purpose grease.
(2) On radial seal rings without rubberized exter-
nal surface, coat outer circumference with sealant.CAUTION: Do not coat partially rubberized seals
with sealant.
(3) Drivenewpinion radial seals into rear axle
housing as far as the stop using Installer 9276 (Fig.
29).
(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) Screw on the collared nut illustrated up to the
marking applied beforehand.
(7) Detach retainer wrench from joint flange.
(8) With a torque wrench, measure torque to
rotate pinion and record measurement.
Fig. 26 COLLARED NUT
1 - PINION FLANGE
2 - COLLARED NUT
Fig. 27 FLANGE PULLER
1 - FLANGE PULLER
2 - PINION FLANGE
Fig. 28 PINION SEALS
1 - SEALS
2 - AXLE
3 - 22 REAR AXLEVA

CRANKSHAFT OIL SEAL -
REAR
REMOVAL
This must be done with the transmission removed
from the vehicle.
(1) Disconnect the negative battery cable.
(2) Raise and support the vehicle.
(3) Drain the engine oil.
NOTE: Loosen all of the oil pan bolts to assure that
the oil pan gasket is not damaged when removing
the rear main oil seal and end cover assembly.
NOTE: Inspect the oil pan gasket for damage. If the
oil pan gasket is damaged, remove the oil pan and
replace the oil pan gasket.
(4) Loosen the oil pan bolts.
(5) Remove the flywheel.CAUTION: Care must be taken when removing the
rear main seal and adaptor assembly. Failure to do
so will result in damage to the oil pan gasket.
(6) Remove the rear main seal/adaptor retaining
bolts and carefully pry the adaptor from the crank-
case at the adaptor shoulders (Fig. 29).
INSTALLATION
NOTE: Thoroughly clean all mating surfaces with
the appropriate solvents to assure that no grease or
oil is present during reassembly.
NOTE: Carefully position the rear main seal/adaptor
evenly onto the assembly sleeve. The rear main oil
seal lip MUST NOT roll over the edge of the tool.
(1) Position the rear main oil seal/adaptor with
assembly sleeve onto the crankshaft so that the
dowel sleeves fit into the guide holes (Fig. 29). Care
must be taken so that the oil pan gasket is not dam-
aged.
Fig. 29 REAR MAIN SEAL/ADAPTER
1 - FLYWHEEL
2 - FLYWHEEL BOLTS
3 - SPECIAL TOOL 8944
4 - REAR CRANKSHAFT OIL SEAL
5 - REAR CRANKSHAFT SEAL ADAPTER6 - CRANKSHAFT
7 - ALIGNMENT DOWELS
8 - REAR CRANKSHAFT SEAL ADAPTER RETAINING BOLT
9 - OIL PAN TO REAR CRANKSHAFT SEAL ADAPTER
RETAINING BOLT
VAENGINE 9 - 37