2005 MERCEDES-BENZ SPRINTER wheel

REMOVAL - REAR (SRW)
(1) Raise and support the vehicle.
(2) Remove the rear wheels.
(3) Remove the rear disc brake pads (Fig. 25).
(4) Remove the disc brake caliper adapter (Fig.
25).
(5) Apply the parking brake.
(6) Install two lug studs to secure the disc brake
rotor when the locking bolt is removed.
(7) Remove the locking bolt for the disc brake rotor
(Fig. 25).
(8) Remove the two lug nuts.
(9) Release the parking brake.
(10) loosen the park brake adjuster to allow clear-
ance for the rotor removal (Fig. 25).
(11) Remove the rear disc brake rotor.
REMOVAL - FRONT (DRW)
(1) Raise and support the vehicle.
(2) Remove the front wheels.
(3) Remove the front brake pads (Fig. 26).
(4) Remove the caliper adapter (Fig. 26).
(5) Remove the wheel flange ring (Fig. 26).
(6) Install two lug studs to secure the disc brake
rotor when the locking bolt is removed.
(7) Remove the locking bolt for the disc brake rotor
(Fig. 26).
(8) Remove the two lug nuts.
(9) Remove the disc brake rotor (Fig. 26).
REMOVAL - REAR (DRW)
(1) Raise and support the vehicle.
(2) Remove the rear wheels.
(3) Remove the rear disc brake pads (Fig. 27).
Fig. 24 FRONT DISC BRAKE ROTOR
1 - CALIPER ADAPTER BOLT
2 - CALIPER ADAPTER
3 - GUIDE BOLT
4 - WEAR INDICATOR
5 - DISC BRAKE CALIPER
6 - DISC BRAKE PADS
7 - LOCKING BOLT
8 - DISC BRAKE ROTOR
Fig. 25 REAR DISC BRAKE ROTOR
1-M8BOLT
2 - CALIPER ADAPTER
3 - DISC BRAKE ROTOR
4 - LOCKING BOLT
5 - DISC BRAKE PADS
6 - RATTLE SPRING
7 - DISC BRAKE CALIPER
8 - GUIDE BOLT
9 - COVER
10 - WEAR INDICATOR
Fig. 26 FRONT DISC BRAKE ROTOR WITH DUAL
REAR WHEELS
1 - ADAPTER BOLT
2 - ADAPTER
3 - GUIDE PIN/BOLT
4 - WEAR INDICATOR WIRE
5 - DISC BRAKE CALIPER
6 - DISC BRAKE PADS
7 - WHEEL FLANGE RING MOUNTING BOLT
8 - WHEEL FLANGE RING
9 - LOCKING BOLT
10 - DISC BRAKE ROTOR
5 - 20 BRAKES - BASEVA
ROTORS (Continued)

(4) Remove the disc brake caliper adapter (Fig.
27).
(5) Apply the parking brake.
(6) Install two lug studs to secure the disc brake
rotor when the locking bolt is removed.
(7) Remove the wheel flange ring (Fig. 27).
(8) Remove the locking bolt for the disc brake rotor
(Fig. 27).
(9) Remove the two lug nuts.
(10) Release the parking brake.
(11) loosen the park brake adjuster to allow clear-
ance for the rotor removal (Fig. 27).
(12) Remove the rear disc brake rotor.
INSTALLATION
INSTALLATION - FRONT (SRW)
(1) Install the disc brake rotor to the hub and
install two lug studs to hold rotor in place.
(2) Install the locking bolt for the rotor (Fig. 24).
Tighten to 23 N´m (204 in. lbs.).
(3) Install the disc brake caliper adapter (Fig. 24).
Tighten to 170 N´m (125 ft. lbs.) (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - INSTALLATION).
(4) Install the brake pads (Refer to 5 - BRAKES/
HYDRAULIC/MECHANICAL/BRAKE PADS/SHOES
- INSTALLATION) (Fig. 24).
(5) Press and release the brake pedal several times
until pressure has built up.(6) Check fluid in reservoir and correct if neces-
sary.
(7) Install the front wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - INSTALLATION).
(8) Lower the vehicle.
INSTALLATION - REAR (SRW)
(1) Install the disc brake rotor to the hub and
install two lug studs to hold rotor in place (Fig. 25).
(2) Apply the parking brake.
(3) Install the locking bolt for the rotor (Fig. 25).
Tighten to 23 N´m (204 in. lbs.).
(4) Install the disc brake caliper adapter (Fig. 25).
Tighten to 90 N´m (66 ft. lbs.) (Refer to 5 - BRAKES/
HYDRAULIC/MECHANICAL/DISC BRAKE CALI-
PER ADAPTER - INSTALLATION).
(5) Install the brake pads (Refer to 5 - BRAKES/
HYDRAULIC/MECHANICAL/BRAKE PADS/SHOES
- INSTALLATION) (Fig. 25).
(6) Release the parking brake.
(7) Adjust the parking brake (Refer to 5 -
BRAKES/PARKING BRAKE/SHOES - ADJUST-
MENTS).
(8) Press and release the brake pedal several times
until pressure has built up.
(9) Check fluid in reservoir and correct if neces-
sary.
(10) Install the rear wheels.
(11) Lower the vehicle.
INSTALLATION - FRONT (DRW)
(1) Install the disc brake rotor to the hub and
install two lug studs to hold rotor in place.
(2) Install the locking bolt for the rotor (Fig. 26).
Tighten to 23 N´m (204 in. lbs.).
(3) Install the disc brake caliper adapter (Fig. 26).
Tighten to 170 N´m (125 ft. lbs.) (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - INSTALLATION).
(4) Install the wheel flange ring. Tighten to 180
N´m (133 ft. lbs.)
(5) Install the brake pads (Refer to 5 - BRAKES/
HYDRAULIC/MECHANICAL/BRAKE PADS/SHOES
- INSTALLATION) (Fig. 26).
(6) Press and release the brake pedal several times
until pressure has built up.
(7) Check fluid in reservoir and correct if neces-
sary.
(8) Install the front wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - INSTALLATION).
(9) Lower the vehicle.
INSTALLATION - REAR (DRW)
(1) Install the disc brake rotor to the hub and
install two lug studs to hold rotor in place (Fig. 27).
(2) Apply the parking brake.
Fig. 27 REAR DISC BRAKE ROTOR WITH DUAL
REAR WHEELS
1 - ADAPTER BOLT
2 - ADAPTER
3 - GUIDE PIN/BOLT
4 - WEAR INDICATOR
5 - DISC BRAKE CALIPER
6 - RETAINING SPRING
7 - DISC BRAKE PADS
8 - WHEEL FLANGE RING MOUNITNG BOLT
9 - WHEEL FLANGE RING
10 - DISC BRAKE ROTOR
VABRAKES - BASE 5 - 21
ROTORS (Continued)

(3) Install the locking bolt for the rotor (Fig. 27).
Tighten to 23 N´m (204 in. lbs.).
(4) Install the disc brake caliper adapter (Fig. 27).
Tighten to 170 N´m (125 ft. lbs.) (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - INSTALLATION).
(5) Install the wheel flange ring (Fig. 27) Tighten
to 200 N´m (148 ft. lbs.).
(6) Install the brake pads (Refer to 5 - BRAKES/
HYDRAULIC/MECHANICAL/BRAKE PADS/SHOES
- INSTALLATION) (Fig. 27).
(7) Release the parking brake.
(8) Adjust the parking brake (Refer to 5 -
BRAKES/PARKING BRAKE/SHOES - ADJUST-
MENTS).
(9) Press and release the brake pedal several times
until pressure has built up.
(10) Check fluid in reservoir and correct if neces-
sary.
(11) Install the rear wheels.
(12) Lower the vehicle.
SUPPORT PLATE
REMOVAL - REAR
(1) Raise and support the vehicle.
(2) Remove the disc brake caliper adapter (Refer to
5 - BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - REMOVAL).
(3) Remove the disc brake rotor (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
REMOVAL).(4) Remove the rear park brake shoes (Refer to 5 -
BRAKES/PARKING BRAKE/SHOES - REMOVAL).
(5) Remove the park brake cable from he support
plate.
(6) Remove the rear axle bearing (Refer to 3 - DIF-
FERENTIAL & DRIVELINE/REAR AXLE/AXLE
BEARINGS - REMOVAL).
(7) Remove brake support plate.
INSTALLATION - REAR
(1) Press the brake support plate with the axle
bearing onto the axle shaft (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/REAR AXLE/AXLE BEARINGS
- INSTALLATION).
(2) Install the park brake cable to the support
plate.
(3) Install the rear park brake shoes (Refer to 5 -
BRAKES/PARKING BRAKE/SHOES - INSTALLA-
TION).
(4) Install the disc brake rotor (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
INSTALLATION).
(5) Install the disc brake caliper adapter (Refer to
5 - BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - INSTALLATION).
(6) Adjust the rear park brake shoes (Refer to 5 -
BRAKES/PARKING BRAKE/SHOES - ADJUST-
MENTS).
(7) Install the rear wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - INSTALLATION).
PARKING BRAKE
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Pressure Transformer Unit
For Brake Cables To
Frame Crossmember25 Ð 221
Hand Brake Lever To Seat
Frame25 Ð 221
5 - 22 BRAKES - BASEVA
ROTORS (Continued)

(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