2005 MERCEDES-BENZ SPRINTER wheel

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)

DIFFERENTIAL & DRIVELINE
TABLE OF CONTENTS
page page
PROPELLER SHAFT......................1REAR AXLE............................10
PROPELLER SHAFT
TABLE OF CONTENTS
page page
PROPELLER SHAFT
DIAGNOSIS AND TESTING................1
STANDARD PROCEDURE.................3
SPECIFICATIONS........................5
SPECIAL TOOLS........................5
PROPELLER SHAFT
REMOVAL.............................6INSTALLATION..........................6
CENTER BEARING
REMOVAL.............................8
INSTALLATION..........................9
PROPELLER SHAFT
DIAGNOSIS AND TESTING
PROPELLER SHAFT VIBRATION
Out-of-round tires or wheels that are out of bal-
ance, will cause a low frequency vibration.Driveline vibration can be from loose or damaged
engine mounts.
Propeller shaft vibration increases with vehicle
speed. A vibration within a specific speed is not usu-
ally caused by a out of balanced propeller shaft.
Worn universal joints or an incorrect propeller shaft
angle, usually cause such a vibration.
VADIFFERENTIAL & DRIVELINE 3 - 1

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)

(15) If vibration remains unacceptable, preform
the procedure to the front end of the propeller shaft.
(16) Install the wheel and tires. Lower the vehicle.
PROPELLER SHAFT RUNOUT
(1) Clean the propeller shaft surface where the
dial indicator will contact the shaft.
(2) The dial indicator must be installed perpendic-
ular to the shaft surface.
(3) Measure runout at the center and ends of the
shaft away from weld areas, to ensure weld process
will not effect the measurements.
(4) Refer to Runout Specifications chart.
(5) If propeller shaft is out of specification, remove
propeller shaft and index the shaft 180É. Install the
propeller shaft and measure shaft runout again.
(6) If propeller shaft is now within specifications,
mark shaft and yokes for proper orientation.
(7) If propeller shaft runout is not within specifica-
tions, check runout of the transmission and axle.
Correct as necessary and repeat propeller shaft
runout measurement.
(8) Replace propeller shaft if the runout still
exceeds the limits.
RUNOUT SPECIFICATIONS
Front of Shaft 0.020 in. (0.50 mm)
Center of Shaft 0.025 in. (0.63 mm)
Rear of Shaft 0.020 in. (0.50 mm)
note:
Measure front/rear runout approximately 76 mm (3 in.)
from the weld seam at each end of the shaft tube for
tube lengths over 30 inches. For tube lengths under
30 inches, the maximum allowed runout is 0.50 mm
(0.020 in.) for the full length of the tube.
STANDARD PROCEDURE
PROPELLER SHAFT ANGLE
This procedure applies the front and rear propeller
shafts.
(1) Place vehicle in netural.
(2) Raise and support vehicle at the axles as level
as possible.
(3) Remove universal joint snap rings if equipped,
so Inclinometer 7663 base sits flat.
(4) Rotate shaft until transmission case output
yoke bearing is facing downward.
NOTE: Always make measurements from front to
rear and from the same side of the vehicle.
(5) Place Inclinometer 7663 on yoke bearing (A)
parallel to the shaft. Center bubble in sight glass and
record measurement.
Fig. 1 Clamp Screw At Position 1
1 - CLAMP
2 - SCREWDRIVER
Fig. 2 Two Clamp Screws At The Same Position
Fig. 3 Clamp Screws Separated
1-1¤2INCH
VAPROPELLER SHAFT 3 - 3
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)

REAR AXLE
TABLE OF CONTENTS
page page
REAR AXLE
DESCRIPTION.........................10
OPERATION...........................10
DIAGNOSIS AND TESTING................10
STANDARD PROCEDURE - DRAIN AND FILL . . 11
REMOVAL.............................11
INSTALLATION.........................12
SPECIFICATIONS.......................13
SPECIAL TOOLS.......................14
AXLE SHAFTS
REMOVAL.............................15
INSTALLATION.........................15AXLE BEARINGS/SEALS
REMOVAL.............................17
INSTALLATION.........................17
AXLE SHAFTS - DUAL REAR WHEELS
REMOVAL.............................19
INSTALLATION.........................19
AXLE HUB BEARINGS/SEALS
REMOVAL.............................20
INSTALLATION.........................20
PINION SEAL
REMOVAL.............................22
INSTALLATION.........................22
REAR AXLE
DESCRIPTION
The axle housings consist of a cast iron center sec-
tion with axle tubes extending from either side. The
tubes are pressed into and welded to the differential
housing to form a one-piece axle housing. The SRW
axle has semi-floating axle shafts, DRW has full-
floating axle shafts.
NOTE: Axle seals, axle bearings, pinion seal and
differential cover are the only serviceble compo-
nents. If differential is damaged/noisy the axle must
be replaced.
OPERATION
The axle receives power from the transmission
through the rear propeller shaft. The rear propeller
shaft is connected to the pinion gear which rotates
the differential through the gear mesh with the ring
gear bolted to the differential case. The engine power
is transmitted to the axle shafts through the pinion
mate and side gears. The side gears are splined to
the axle shafts.
DIAGNOSIS AND TESTING
NOTE: Axle seals, axle bearings, pinion seals and
differential cover are the only serviceble compo-
nents. If differential is damaged/noisy the axle must
be replaced.
GEAR NOISE
Axle gear noise can be caused by insufficient lubri-
cant, incorrect backlash, incorrect pinion depth, tooth
contact, worn/damaged gears, or the carrier housing
not having the proper offset and squareness.
Gear noise usually happens at a specific speed
range. The noise can also occur during a specific type
of driving condition. These conditions are accelera-
tion, deceleration, coast, or constant load.
When road testing, first warm-up the axle fluid by
driving the vehicle at least 5 miles and then acceler-
ate the vehicle to the speed range where the noise is
the greatest. Shift out-of-gear and coast through the
peak-noise range. If the noise stops or changes
greatly:
²Check for insufficient lubricant.
²Incorrect ring gear backlash.
²Gear damage.
Differential side gears and pinions can be checked
by turning the vehicle. They usually do not cause
noise during straight-ahead driving when the gears
are unloaded. The side gears are loaded during vehi-
cle turns. A worn pinion shaft can also cause a snap-
ping or a knocking noise.
BEARING NOISE
The axle shaft, differential and pinion bearings can
all produce noise when worn or damaged. Bearing
noise can be either a whining, or a growling sound.
Pinion bearingshave a constant-pitch noise. This
noise changes only with vehicle speed. Pinion bearing
noise will be higher pitched because it rotates at a
faster rate. Drive the vehicle and load the differen-
tial. If bearing noise occurs, the rear pinion bearing
is the source of the noise. If the bearing noise is
3 - 10 REAR AXLEVA