2005 MERCEDES-BENZ SPRINTER Service Repair Manual

INSTALLATION
(1) Press center bearing on propeller shaft with
protective caps and washer with Installer 9275 (Fig.
14).(2) Install snap-ring.
(3) Coat propeller shaft spline with universal
grease.
(4) Push rubber boot onto propeller shaft.
(5) Push together propeller shaft. Pay attention to
alignment markings for installation position.
(6) Ensure rubber seal is correctly installed and
attachnewcollar clamps.
(7) Install propeller shaft.
Fig. 14 CENTER BEARING INSTALLATION
1 - INSTALLER
2 - CENTER BEARING
VAPROPELLER SHAFT 3 - 9
CENTER BEARING (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

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)