2005 MERCEDES-BENZ SPRINTER brake

CABLES
REMOVAL
REMOVAL - FRONT
(1) Raise and support the vehicle.
(2) Disconnect the front park brake cable from the
pulley unit.
(3) Remove the front park brake cable from the
hand brake lever (Fig. 29).
(4) Unclip the guides at the frame cross members
for the front cable at the vehicle (Fig. 30).
(5) Pull off the locking clips at the floor opening
and pull the front brake cable down and out (Fig.
30).
(6) Press together the locking ring and pull out the
front brake cable to the front (Fig. 30).
(7) Remove the front park brake cable at the vehi-
cle using special tool 9289.
REMOVAL - REAR
(1) Raise and support the vehicle.
(2) Remove the rear tires.
(3) Remove the park brake shoes.
(4) Remove the park brake cables from the shoe
(Fig. 31).
(5) Remove all the connections on the hand brake
cable (Fig. 31).
(6) Remove the park brake cable lock (Fig. 31).
Observe the installed position of the brake
cable lock for reference on installation.
(7) Remove the hand brake cable from the anchor
plate (Fig. 31).(8) Remove the park brake cable from the vehicle.
Compress the locking ring on the pulley unit.
INSTALLATION
INSTALLATION - FRONT
(1) Install the front park brake cable to the vehi-
cle.
(2) Clip the cable guides at the frame cross mem-
bers (Fig. 32).
(3) Install the front park brake cable to the hand
brake lever (Fig. 29).
(4) Reconnect the front park brake cable to the
pulley unit (Fig. 32).
Fig. 29 FRONT PARK BRAKE CABLE AT LEVER
1 - LOCKING CLIP
2 - LOCKING PIN
3 - CABLE STRAP
Fig. 30 REMOVING FRONT PARK BRAKE CABLE AT
THE VEHICLE
1 - UNCLIP CABLE GUIDES
2 - LOCKING CLIP
3 - LOCKING RING PRESSED TOGETHER
Fig. 31 REAR PARK BRAKE CABLE REMOVE /
INSTALL
1 - PARK BRAKE ADJUSTER
2 - PARK BRAKE CABLE MOUNTING
5 - 24 BRAKES - BASEVA

(5) Adjust the parking park.
(6) Lower the vehicle.
INSTALLATION - REAR
NOTE: Route the park brake cable free of tension
and the risk of chafing.
(1) Install the hand brake cable to the anchor
plate (Fig. 31).
(2) Install the park brake cable lock (Fig. 31).
(3) Install all connections on the hardware cable
(Fig. 31).
(4) Install the park brake cables to the shoe (Fig.
31).
(5) Install the park brake shoes.
(6) Install the rear wheels.
(7) Adjust the park brakes.
(8) Lower the vehicle.
ADJUSTMENTS
ADJUSTMENT - PARKING BRAKE CABLES
(1) Loosen the bolts of the mounting brackets (Fig.
33).
(2) Insert a drill bit or an allen wrench with a 6
mm diameter between the mounting bracket and
front lever (Fig. 33).
(3) Push the mounting bracket back until the front
brake cable is free of play and without tension (Fig.
33).
(4) Tighten the bolts to the mounting bracket
Tighten to 25 N´m (221 in. lbs.) (Fig. 33).(5) Remove the 6 mm diameter drill bit or allen
wrench (Fig. 33).
(6) Tighten the hand brake lever one notch (Fig.
33).
(7) Clamp the eccentric clockwise until the wheels/
disc brake rotors can still be turned with the force of
the hand (Fig. 34).
(8) Tighten the clamp bolt (Fig. 34).
(9) Release the hand brake lever.
(10) Check the wheel for free movement.
Fig. 32 FRONT PARK BRAKE CABLE
1 - RETAINING CLIP
2 - LOCKING PIN
3 - FRONT PARK BRAKE CABLE
4 - RETAINING CLIP
5 - PARK BRAKE CABLE ADJUSTER
Fig. 33 PARK BRAKE ADJUSTER
1 - LOOSEN MOUNTING BOLTS
2-6mmALLEN WRENCH
3 - MOUNTING BOLTS TIGHTENED
4 - FREEPLAY WITH NO TENSION
Fig. 34 PARK BRAKE ADJUSTMENT
1 - ECCENTRIC CLOCKWISE
2 - CLAMP SCREW TIGHTENED
VABRAKES - BASE 5 - 25
CABLES (Continued)

LEVER
REMOVAL
(1) Disconnect the front brake cable from the pul-
ley unit.
(2) Remove the front brake cable from the hand
brake lever (Fig. 29).
(3) Remove the circle cover (Fig. 35).
(4) Remove the bolts on the hand brake lever (Fig.
35).
(5) Pull the cover off the hand brake lever (Fig.
35).
(6) Disconnect the hand brake check switch and
wiring harness from the hand brake lever (Fig. 35).
(7) Remove the hand brake lever (Fig. 35).
INSTALLATION
(1) Install the hand brake lever (Fig. 35).
(2) Reconnect the hand brake check switch and the
wiring harness to the hand brake lever (Fig. 35).
(3) Install the cover to the hand brake lever (Fig.
35).
(4) Install the bolts on the hand brake lever.
Tighten to 25 N´m (221 in. lbs.) (Fig. 35).
(5) Install the circle cover (Fig. 35).
(6) Install the front brake cable to the hand brake
lever.
(7) Connect the front brake cable to the pulley unit
(Fig. 35).
SHOES
REMOVAL
REMOVAL - (SRW)
(1) Raise and support the vehicle.
(2) Remove the rear wheels.
(3) Remove the disc brake rotor.
(4) Disconnect the front park brake cable from the
pulley unit.Do not remove the rear park brake
cables.
(5) Remove the retracting springs using special
tool 9280 (Fig. 36).
(6) Remove the adjuster (Fig. 36).
(7) Remove the pressure springs using special tool
9281 (Fig. 36).
(8) Remove the rear park brake shoes (Fig. 36).
Pull the park brake shoes apart at the bottom
and remove them together with the adjuster.
REMOVAL - (DRW)
(1) Raise and support the vehicle.
(2) Remove the rear wheels.
(3) Remove the wheel flange ring.
(4) Remove the disc brake rotor.
(5) Disconnect the front park brake cable from the
pulley unit.Do not remove the rear park brake
cables.
(6) Remove the retracting springs (Fig. 37).
Fig. 35 HAND BRAKE LEVER
1 - LOCKING PIN
2 - COVER
3 - HAND BRAKE LEVER
4 - HAND BRAKE CHECK SWITCH
5 - WIRING HARNESS
6 - BOLT
7 - HAND BRAKE CABLE
8 - BOLT
9 - RETAINING CLIP
10 - CIRCLE COVER
Fig. 36 PARK BRAKE SHOES
1 - PARK BRAKE SHOES
2 - PRESSURE SPRING
3 - RETRACTING SPRING (SHORT HOOK EYE)
4 - RETRACTING SPRING (LONG HOOK EYE)
5 - CABLE LOCK
6 - ADJUSTER
5 - 26 BRAKES - BASEVA

(7) Remove the adjuster (Fig. 37).
(8) Remove the pressure springs (Fig. 37). by
depressing with your fingers and twisting.
(9) Remove the rear park brake shoes (Fig. 37).
Pull the park brake shoes apart at the bottom
and remove them together with the adjuster.
CLEANING - REAR DRUM IN HAT BRAKE
Clean the individual brake components, including
the support plate exterior, with a water dampened
cloth or with brake cleaner. Do not use any other
cleaning agents. Remove light rust and scale from
the brake shoe contact pads on the support plate
with fine sandpaper.
INSTALLATION
INSTALLATION - (SRW)
NOTE: Preassemble the retracting spring with the
short hook eye from the inside together with the
adjuster wheel at the bottom. Fit the preassembled
park brake shoes on the brake carrier.
(1)Ensure that the cable lock moves easily
before installing shoes.Install the park brake
shoes.(2) Install the lower retracting spring using special
tool 9280.
(3) Install the hold down springs using special tool
9281.
(4) Install the upper retracting spring using spe-
cial tool 9280.
(5) Install the adjuster.
(6) Install the front park brake cable to the pulley
unit.
(7) Install the disc brake rotor.
(8) Install the rear wheels.
(9) Adjust the parking brakes.
(10) Lower the vehicle.
(11) Pump the brake pedal several times to check
the operation of the brakes before moving vehicle.
INSTALLATION - (DRW)
NOTE: Preassemble the retracting spring with the
short hook eye from the inside together with the
adjuster wheel at the bottom. Fit the preassembled
park brake shoes on the brake carrier.
(1)Ensure that the cable lock moves easily
before installing shoes.Install the park brake
shoes.
(2) Install the lower retracting spring.
(3) Install the pressure hold down springs by
depressing with your fingers and twisting to lock in
place.
(4) Install the upper retracting spring.
(5) Install the adjuster.
(6) Install the front park brake cable to the pulley
unit.
(7) Install the disc brake rotor.
(8) Install the rear wheel flange ring. Tighten to
200 N´m (148 ft. lbs.).
(9) Install the rear wheels.
(10) Adjust the parking brakes.
(11) Lower the vehicle.
(12) Pump the brake pedal several times to check
the operation of the brakes before moving vehicle.
ADJUSTMENTS
ADJUSTMENT
(1) Raise and support the vehicle.
(2) Remove the rear wheels.
(3) Turn the adjusting wheel through the hole of
the wheel lug bolt until it is no longer possible to
rotate the rear wheel (Fig. 38).
Fig. 37 PARK BRAKE SHOES WITH DUAL REAR
WHEELS
1 - HOLD DOWN PIN
2 - PRESSURE SPRING
3 - ADJUSTER
4 - UPPER RETRACTING SPRING
5 - LOWER RETRACTING SPRING
6 - CABLE LOCK
7 - LOCKING PIN
8 - BRAKE CABLE
9 - PARK BRAKE SHOE
VABRAKES - BASE 5 - 27
SHOES (Continued)

(4) Loosen the adjusting wheel 3-4 teeth divisions
(Fig. 38).(5) Inspect the clearance, or a slight drag when
rotating the wheel/rear disc brake rotor (Fig. 39).
(6) Install rear wheels.
(7) Lower the vehicle and test the park brake sys-
tem to hold the vehicle.
Fig. 38 STAR WHEEL ADJUSTER
1 - LEFT HAND PARK BRAKE SHOES APPLIED
2 - RIGHT HAND PARK BRAKE SHOES RELEASED
3 - FLAT BLADED TOOL
Fig. 39 ADJUSTING REAR PARK BRAKE SHOES
1 - FRONT BRAKE CABLE
2 - SHOE ADJUSTER
3 - REAR BRAKE CABLES
4 - PARK BRAKE CABLE ADJUSTER
5 - 28 BRAKES - BASEVA
SHOES (Continued)

BRAKES - ABS
TABLE OF CONTENTS
page page
BRAKES - ABS
SPECIFICATIONS - TORQUE CHART........29
ELECTRICAL
DESCRIPTION.........................29
OPERATION...........................29
FRONT WHEEL SPEED SENSOR
REMOVAL.............................30
INSTALLATION.........................30
REAR WHEEL SPEED SENSOR
REMOVAL.............................30INSTALLATION.........................31
TONE WHEEL
REMOVAL.............................31
INSTALLATION.........................31
HCU (HYDRAULIC CONTROL UNIT)
DESCRIPTION.........................31
REMOVAL.............................31
INSTALLATION.........................32
BRAKES - ABS
SPECIFICATIONS - TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Brake Lines To Hydraulic
unit16 Ð 12
ELECTRICAL
DESCRIPTION
NOTE: Wheel speed sensor should be installed all
the way into the clamping bushings, the wheel
speed sensor will self adjust when the vehicle is
moved.
The ABS brake system uses 4 wheel speed sensors.
A sensor is mounted to each front hub/bearings in
the front. A rear sensor is mounted to each rear sup-
port plate.
OPERATION
The Wheel Speed Sensor consists of a magnet sur-
rounded by windings from a single strand of wire.
The sensor sends a small AC signal to the CAB. This
signal is generated by magnetic induction. The mag-
netic induction is created when a toothed sensor ring
(exciter ring or tone wheel) passes the stationary
magnetic WSS.When the ring gear is rotated, the exciter ring
passes the tip of the WSS. As the exciter ring tooth
approaches the tip of the WSS, the magnetic lines of
force expand, causing the magnetic field to cut across
the sensor's windings. This, in turn causes current to
flow through the WSS circuit (Fig. 1) in one direc-
tion. When the exciter ring tooth moves away from
the sensor tip, the magnetic lines of force collapse
cutting the winding in the opposite direction. This
causes the current to flow in the opposite direction.
Every time a tooth of the exciter ring passes the tip
of the WSS, an AC signal is generated. Each AC sig-
nal (positive to negative signal or sinewave) is inter-
preted by the CAB. It then compares the frequency of
the sinewave to a time value to calculate vehicle
speed. The CAB continues to monitor the frequency
to determine a deceleration rate that would indicate
a possible wheel-locking tendency.
The signal strength of any magnetic induction sen-
sor is directly affected by:
²Magnetic field strength; the stronger the mag-
netic field, the stronger the signal
VABRAKES - ABS 5 - 29

²Number of windings in the sensor; more wind-
ings provide a stronger signal
²Exciter ring speed; the faster the exciter ring/
tone wheel rotates, the stronger the signal will be
²Distance between the exciter ring teeth and
WSS; the closer the WSS is to the exciter ring/tone
wheel, the stronger the signal will be.
FRONT WHEEL SPEED
SENSOR
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the front wheels.
(3) Pull the wheel speed sensor out of the front
wheel hub (Fig. 2).
(4)Only due this step if sensor replacement is
necessary.Cut through the wheel speed sensor
cable at an easily accessible point (Fig. 2)
INSTALLATION
(1) Connect separate wheel speed sensor cables
with shrink-fit sleeves and shrink-fit tubing (Fig.
2).Only due this step if replacing the sensor.
(2) Install the wheel speed sensor all the way into
the front wheel hub the wheel speed sensor will self
adjust when the vehicle is moved (Fig. 2).
(3) Install the front wheels.(4) Lower the vehicle.
REAR WHEEL SPEED SENSOR
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the rear wheels.
(3) Pull the wheel speed sensor out of the mount-
ing hole in the axle supporting tube (Fig. 3).
(4)Only due this step if sensor replacement is
necessary.Cut through the wheel speed sensor
cable at an easily accessible point (Fig. 3)
Fig. 1 Operation of the Wheel Speed Sensor
1 - MAGNETIC CORE
2 - CAB
3 - AIR GAP
4 - EXCITER RING
5 - COIL
Fig. 2 FRONT WHEEL SPEED SENSOR
1 - SHRINK-FIT SLEEVE
2 - CLAMPING BUSHING
3 - SPEED SENSOR
4 - SHRINK TUBE
Fig. 3 REAR WHEEL SPEED SENSORS
1 - SHRINK-FIT SLEEVE
2 - SPEED SENSOR
3 - CLAMPING BUSHING
4 - SHRINK TUBE
5 - 30 BRAKES - ABSVA
ELECTRICAL (Continued)

INSTALLATION
(1) Connect separate wheel speed sensor cables
with shrink-fit sleeves and shrink-fit tubing (Fig.
3).Only due this step if replacing the sensor.
(2) Install the wheel speed sensor all the way into
the axle tube, the wheel speed sensor will self adjust
when the vehicle is moved (Fig. 3).
(3) Install the rear wheels.
(4) Lower the vehicle.
TONE WHEEL
REMOVAL
(1) Remove the hub/bearing assembly (DRW)
(Refer to 3 - DIFFERENTIAL & DRIVELINE/REAR
AXLE/AXLE BEARINGS - REMOVAL).
(2) Insert a hooked prybar between the hub/bear-
ing and the inside of the tone wheel and pry upwards
slightly and work your way around the tone wheel
until the wheel is loose (Fig. 4).
(3) Remove the tone wheel.
INSTALLATION
(1) Install the tone wheel to the hub/bearing with
a thin bead of silicone around the tone wheel.
(2) Tap the tone wheel down with a soft hammer
until seated.
(3) Install the hub/bearing (DRW) (Refer to 3 -
DIFFERENTIAL & DRIVELINE/REAR AXLE/AXLE
BEARINGS - INSTALLATION).
HCU (HYDRAULIC CONTROL
UNIT)
DESCRIPTION
The HCU consists of a valve body, pump motor, low
pressure accumulators, inlet valves, outlet valves and
noise attenuators.
REMOVAL
NOTE: Store the Hydraulic Control Unit in an
upright position only.
(1) Disconnect the ground cable at the battery.
The ignition switch must be switched to the off
position when disconnecting the battery cable.
(2) Disconnect the multiplug from the control mod-
ule (Fig. 5).
(3) Disconnect the brake lines from the hydraulic
control unit (Fig. 5).Mark the brake lines for
reinstallation, also seal off the connections and
lines to prevent contamination.
(4) Remove the hydraulic control unit from the
bracket (Fig. 5).
(5) Check the rubber mounts on the bracket.
(Replace if necessary) (Fig. 5).
Fig. 4 TONE WHEEL REMOVAL
1 - HOOKED PRYBAR
2 - TONE WHEEL
3 - HUB/BEARING ASSEMBLY
Fig. 5 HYDRAULIC CONTROL UNIT (ABS)
1 - BRAKE LINES
2 - HCU WITH CONTROL MODULE
3 - ABS/ABD CONTROL MODULE MULTIPLUG
4 - RUBBER SUPPORT
VABRAKES - ABS 5 - 31
REAR WHEEL SPEED SENSOR (Continued)