wheel MERCEDES-BENZ SPRINTER 2006 Service Manual

(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

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

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

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

(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