2006 MERCEDES-BENZ SPRINTER torque

TORQUE CONVERTER CLUTCH (TCC)
In a standard torque converter, the impeller (2)
and turbine (1) are rotating at about the same speed
and the stator (3) is freewheeling, providing no
torque multiplication. By applying the turbine's pis-
ton and friction material (9) (Fig. 250), a total con-
verter engagement can be obtained. The result of this
engagement is a direct 1:1 mechanical link between
the engine and the transmission.
The clutch can be engaged in second, third, fourth,
and fifth gear ranges.
The TCM controls the torque converter by way of
internal logic software. The programming of the soft-
ware provides the TCM with control over the torque
converter solenoid. There are four output logic states
that can be applied as follows:
²No EMCC
²Partial EMCC
²Full EMCC
²Gradual-to-no EMCC
NO EMCC
Under No EMCC conditions, the TCC Solenoid is
OFF. There are several conditions that can result inNO EMCC operations. No EMCC can be initiated
due to a fault in the transmission or because the
TCM does not see the need for EMCC under current
driving conditions.
PARTIAL EMCC
Partial EMCC operation modulates the TCC Sole-
noid (duty cycle) to obtain partial torque converter
clutch application. Partial EMCC operation is main-
tained until Full EMCC is called for and actuated.
During Partial EMCC some slip does occur. Partial
EMCC will usually occur at low speeds, low load and
light throttle situations.
FULL EMCC
During Full EMCC operation, the TCM increases
the TCC Solenoid duty cycle to full ON after Partial
EMCC control brings the engine speed within the
desired slip range of transmission input speed rela-
tive to engine rpm.
GRADUAL - TO - NO EMCC
This operation is to soften the change from Full or
Partial EMCC to No EMCC. This is done at mid-
throttle by decreasing the TCC Solenoid duty cycle.
REMOVAL
(1) Remove transmission and torque converter
from vehicle.
(2) Place a suitable drain pan under the converter
housing end of the transmission.
CAUTION: Verify that transmission is secure on the
lifting device or work surface, the center of gravity
of the transmission will shift when the torque con-
verter is removed creating an unstable condition.
The torque converter is a heavy unit. Use caution
when separating the torque converter from the
transmission.
(3) Pull the torque converter forward until the cen-
ter hub clears the oil pump seal.
(4) Separate the torque converter from the trans-
mission.
Fig. 250 Torque Converter Lock-up Clutch
1 - TURBINE
2 - IMPELLER
3-STATOR
4 - INPUT SHAFT
5 - STATOR SHAFT
6 - PISTON
7 - COVER SHELL
8 - INTERNALLY TOOTHED DISC CARRIER
9 - CLUTCH PLATE SET
10 - EXTERNALLY TOOTHED DISC CARRIER
11 - TURBINE DAMPER
VAAUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 183

INSTALLATION
Check converter hub and drive flats for sharp
edges, burrs, scratches, or nicks. Polish the hub and
flats with 320/400 grit paper or crocus cloth if neces-
sary. The hub must be smooth to avoid damaging the
pump seal at installation.
(1) Lubricate oil pump seal lip with transmission
fluid.
(2)
Place torque converter in position on transmission.
CAUTION: Do not damage oil pump seal or con-
verter hub while inserting torque converter into the
front of the transmission.
(3) Align torque converter to oil pump seal open-
ing.
(4) Insert torque converter hub into oil pump.
(5) While pushing torque converter inward, rotate
converter until converter is fully seated in the oil
pump gears.
(6) Check converter seating with a scale and
straightedge (Fig. 251). Surface of converter lugs
should be at least 19 mm (3/4 in.) to rear of straight-
edge when converter is fully seated.
(7) If necessary, temporarily secure converter with
C-clamp attached to the converter housing.
(8) Install the transmission in the vehicle.
(9) Fill the transmission with the recommended
fluid.
TORQUE CONVERTER HUB
SEAL
REMOVAL
(1) Remove the torque converter (Refer to 21 -
TRANSMISSION/AUTOMATIC - NAG1/TORQUE
CONVERTER - REMOVAL).(2) Remove the torque converter hub seal with
suitable screw and slide hammer.
INSTALLATION
(1) Position the torque converter hub seal (1) (Fig.
252) over the input shaft and against the transmis-
sion oil pump.
(2) Using Seal Installer 8902A (2) (Fig. 253),
install a new torque converter hub seal.
(3) Install the torque converter (Refer to 21 -
TRANSMISSION/AUTOMATIC - NAG1/TORQUE
CONVERTER - INSTALLATION).
Fig. 251 Torque Converter Installation Depth
1 - TORQUE CONVERTER
2 - TRANSMISSION HOUSING
Fig. 252 Position Torque Converter Hub Seal
1 - TORQUE CONVERTER HUB SEAL
2 - INPUT SHAFT
Fig. 253 Install Torque Converter Hub Seal
1 - OIL PUMP
2 - SEAL INSTALLER 8902A
21 - 184 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATIONVA

TIRES / WHEELS
TABLE OF CONTENTS
page page
TIRES/WHEELS
DIAGNOSIS AND TESTING - TIRE AND
WHEEL RUNOUT......................1
STANDARD PROCEDURE
STANDARD PROCEDURE - MATCH
MOUNTING...........................2
STANDARD PROCEDURE - TIRE AND
WHEEL BALANCE......................4
STANDARD PROCEDURE - TIRE ROTATION . 6
SPECIFICATIONS
TORQUE CHART......................7
TIRES
DESCRIPTION
DESCRIPTION - TIRES..................7
DESCRIPTION - RADIAL ± PLY TIRES......7
DESCRIPTION - TIRE PRESSURE FOR
HIGH SPEEDS.........................8
DESCRIPTION - REPLACEMENT TIRES.....8
DESCRIPTION - TIRE INFLATION
PRESSURES..........................8
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - PRESSURE
GAUGES.............................9
DIAGNOSIS AND TESTING - TIRE NOISE
OR VIBRATION........................9
DIAGNOSIS AND TESTING - TREAD WEAR
INDICATORS..........................9DIAGNOSIS AND TESTING - TIRE WEAR
PATTERNS...........................9
DIAGNOSIS AND TESTING - TIRE/VEHICLE
LEAD...............................10
STANDARD PROCEDURE - REPAIRING
LEAKS..............................12
CLEANING............................12
SPECIFICATIONS
TIRES..............................12
SPARE TIRE CARRIER
REMOVAL.............................12
INSTALLATION.........................12
WHEELS
DESCRIPTION.........................13
OPERATION...........................13
DIAGNOSIS AND TESTING
WHEEL INSPECTION..................13
STANDARD PROCEDURE
STANDARD PROCEDURE - WHEEL
REPLACEMENT.......................13
STANDARD PROCEDURE - DUAL REAR
WHEEL INSTALLATION.................13
REMOVAL.............................14
INSTALLATION.........................15
TIRES / WHEELS
DIAGNOSIS AND TESTING - TIRE AND WHEEL
RUNOUT
Radial runout is the difference between the high
and low points on the tire or wheel (Fig. 1).
Lateral runout is thewobbleof the tire or
wheel.
Fig. 1 Checking Tire/Wheel/Hub Runout
1 - RADIAL RUNOUT
2 - LATERAL RUNOUT
VATIRES/WHEELS 22 - 1

Radial runout of more than 1.5 mm (.060 inch)
measured at the center line of the tread may cause
the vehicle to shake.
Lateral runout of more than 2.0 mm (.080 inch)
measured near the shoulder of the tire may cause the
vehicle to shake.
Sometimes radial runout can be reduced. Relocate
the wheel and tire assembly on the mounting studs
(See Method 1). If this does not reduce runout to an
acceptable level, the tire can be rotated on the wheel.
(See Method 2).
METHOD 1 (RELOCATE WHEEL ON HUB)
(1) Drive vehicle a short distance to eliminate tire
flat spotting from a parked position.
(2) Check wheel bearings and adjust if adjustable
or replace if necessary.
(3) Check the wheel mounting surface.
(4) Relocate wheel on the mounting, two studs
over from the original position.
(5) Tighten wheel nuts until all are properly
torqued, to eliminate brake distortion.
(6) Check radial runout. If still excessive, mark
tire sidewall, wheel, and stud at point of maximum
runout and proceed to Method 2.
METHOD 2 (RELOCATE TIRE ON WHEEL)
NOTE: Rotating the tire on wheel is particularly
effective when there is runout in both tire and
wheel.
(1) Remove tire from wheel and mount wheel on
service dynamic balance machine.
(2) Check wheel radial runout (Fig. 2) and lateral
runout (Fig. 3).
²STEEL WHEELS: Radial runout 0.031 in., Lat-
eral runout 0.031 in. (maximum)
²ALUMINUM WHEELS: Radial runout 0.020 in.,
Lateral runout 0.025 in. (maximum)
(3) If point of greatest wheel lateral runout is near
original chalk mark, remount tire 180 degrees.
Recheck runout, Refer to match mounting proce-
dure.
STANDARD PROCEDURE
STANDARD PROCEDURE - MATCH MOUNTING
Wheels and tires are match mounted at the factory.
This means that the high spot of the tire is matched
to the low spot on the wheel rim. Each are marked
with a bright colored temporary label on the out-
board surface for alignment. The wheel is also
Fig. 2 Radial Runout
1 - MOUNTING CONE
2 - SPINDLE SHAFT
3 - WING NUT
4 - PLASTIC CUP
5 - DIAL INDICATOR
6 - WHEEL
7 - DIAL INDICATOR
Fig. 3 Lateral Runout
1 - MOUNTING CONE
2 - SPINDLE SHAFT
3 - WING NUT
4 - PLASTIC CUP
5 - DIAL INDICATOR
6 - WHEEL
7 - DIAL INDICATOR
22 - 2 TIRES/WHEELSVA

SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
3500 Series 190 +10 140 +10 ±
2500 Series 240 +10 177 +10 ±
TIRES
DESCRIPTION
DESCRIPTION - TIRES
Tires are designed and engineered for each specific
vehicle. They provide the best overall performance
for normal operation. The ride and handling charac-
teristics match the vehicle's requirements. With
proper care they will give excellent reliability, trac-
tion, skid resistance, and tread life.
Driving habits have more effect on tire life than
any other factor. Careful drivers will obtain in most
cases, much greater mileage than severe use or care-
less drivers. A few of the driving habits which will
shorten the life of any tire are:
²Rapid acceleration
²Severe brake applications
²High speed driving
²Excessive speeds on turns
²Striking curbs and other obstacles
Radial-ply tires are more prone to irregular tread
wear. It is important to follow the tire rotation inter-
val shown in the section on Tire Rotation, (Refer to
22 - TIRES/WHEELS - STANDARD PROCEDURE).
This will help to achieve a greater tread life.
TIRE IDENTIFICATION
Tire type, size, aspect ratio and speed rating are
encoded in the letters and numbers imprinted on the
side wall of the tire. Refer to the chart to decipher
the tire identification code (Fig. 11).
Performance tires have a speed rating letter after
the aspect ratio number. The speed rating is not
always printed on the tire sidewall. These ratings
are:
²Qup to 100 mph
²Rup to 106 mph
²Sup to 112 mph
²Tup to 118 mph
²Uup to 124 mph²Hup to 130 mph
²Vup to 149 mph
²Zmore than 149 mph (consult the tire manu-
facturer for the specific speed rating)
An All Season type tire will have eitherM+S,M
&SorM±S(indicating mud and snow traction)
imprinted on the side wall.
TIRE CHAINS
Tire snow chains may be used oncertainmodels.
Refer to the Owner's Manual for more information.
DESCRIPTION - RADIAL ± PLY TIRES
Radial-ply tires improve handling, tread life and
ride quality, and decrease rolling resistance.
Fig. 11 Tire Identification
VATIRES/WHEELS 22 - 7

STANDARD PROCEDURE - REPAIRING LEAKS
For proper repairing, a radial tire must be removed
from the wheel. Repairs should only be made if the
defect, or puncture, is in the tread area (Fig. 17). The
tire should be replaced if the puncture is located in
the sidewall.
Deflate tire completely before removing the tire
from the wheel. Use lubrication such as a mild soap
solution when dismounting or mounting tire. Use
tools free of burrs or sharp edges which could dam-
age the tire or wheel rim.
Before mounting tire on wheel, make sure all rust
is removed from the rim bead and repaint if neces-
sary.
Install wheel on vehicle, and tighten to proper
torque specification, (Refer to 22 - TIRES/WHEELS/
WHEELS - SPECIFICATIONS).
CLEANING
Remove the protective coating on the tires before
delivery of a vehicle. This coating may cause deteri-
oration of the tires.
To remove the protective coating, apply warm
water and let it soak for a few minutes. Afterwards,
scrub the coating away with a soft bristle brush.
Steam cleaning may also be used to remove the coat-
ing.
NOTE: DO NOT use gasoline, mineral oil, oil-based
solvent or a wire brush for cleaning.
SPECIFICATIONS
TIRES
SPECIFICATIONS
DESCRIPTION SPECIFICATION
TIRE P225/70R15C
LR D
TIRE LT225/75R16
LR E
TIRE P
SPARE TIRE CARRIER
REMOVAL
(1) Open the back doors.
(2) Loosen the bolts for the spare tire hold down
(Fig. 18).
(3) Push up on the spare tire carrier and push the
hold downs to the side and lower (Fig. 18).
(4) Remove the spare tire.
INSTALLATION
(1) Install the spare tire to the spare tire carrier
(Fig. 18).
(2) Raise the tire and wheel assmbly and hook on
the hold downs (Fig. 18).
(3) Then tighten the hold downs to secure the
spare tire in place and then close the doors.
Fig. 17 TIRE REPAIR AREA
1 - TIRE REPAIR AREA
Fig. 18 SPARE TIRE
1 - HOLD DOWNS
2 - SPARE TIRE
3 - SPARE TIRE CARRIER
22 - 12 TIRES/WHEELSVA

WHEELS
DESCRIPTION
Original equipment wheels are designed for the
specified Maximum Vehicle Capacity.
All models use steel or aluminum wheels.
Aluminum wheels require special balance weights
and alignment equipment.
(1) On vehicles equipped with dual rear wheels,
The slots in the wheel must be aligned to provide
access to the valve stem.
OPERATION
The wheel (Fig. 19) has raised sections between
the rim flanges and the rim well. Initial inflation of
the tire forces the bead over these raised sections. In
case of tire failure, the raised sections hold the tire
in position on the wheel until the vehicle can be
brought to a safe stop.
DIAGNOSIS AND TESTING
WHEEL INSPECTION
Inspect wheels for:
²Excessive run out
²Dents or cracks
²Damaged wheel lug nut holes
²Air Leaks from any area or surface of the rim
NOTE: Do not attempt to repair a wheel by hammer-
ing, heating or welding.
If a wheel is damaged an original equipment
replacement wheel should be used. When obtaining
replacement wheels, they should be equivalent in
load carrying capacity. The diameter, width, offset,pilot hole and bolt circle of the wheel should be the
same as the original wheel.
WARNING: FAILURE TO USE EQUIVALENT
REPLACEMENT WHEELS MAY ADVERSELY
AFFECT THE SAFETY AND HANDLING OF THE
VEHICLE. USED WHEELS ARE NOT RECOM-
MENDED. THE SERVICE HISTORY OF THE WHEEL
MAY HAVE INCLUDED SEVERE TREATMENT OR
VERY HIGH MILEAGE. THE RIM COULD FAIL WITH-
OUT WARNING.
STANDARD PROCEDURE
STANDARD PROCEDURE - WHEEL REPLACE-
MENT
The wheel stud/lugs are designed for specific appli-
cations. They must be replaced with equivalent parts.
Do not use replacement parts of lesser quality or a
substitute design.
Before installing the wheel, be sure to remove any
build up of corrosion on the wheel mounting surfaces.
Ensure wheels are installed with good metal-to-metal
contact. Improper installation could cause loosening
of wheel nuts. This could affect the safety and han-
dling of your vehicle.
To install the wheel, first position it properly on
the mounting surface. All wheel nuts should then be
tightened just snug. Gradually tighten them in
sequence to the proper torque specification.Never
use oil or grease on studs.
Wheels must be replaced if they have:
²Excessive runout
²Bent or dented
²Leak air through welds
²Have damaged bolt holes
Wheel repairs employing hammering, heating, or
welding are not allowed.
Original equipment wheels are available through
your dealer. Replacement wheels from any other
source should be equivalent in:
²Load carrying capacity
²Diameter
²Width
²Offset
²Mounting configuration
Failure to use equivalent replacement wheels may
affect the safety and handling of your vehicle.
Replacement withusedwheels is not recommended.
Their service history may have included severe treat-
ment.
STANDARD PROCEDURE - DUAL REAR WHEEL
INSTALLATION
The tires on both wheels must be completely raised
off the ground when tightening the lug nuts. This
Fig. 19 Safety Rim
1 - FLANGE
2 - RIDGE
3 - WELL
VATIRES/WHEELS 22 - 13

will ensure correct wheel centering and maximum
wheel clamping.
Before installing the wheel to the wheel ring flange
make sure that all the cone washers are installed on
the wheel flange ring (Fig. 20).
The dual rear wheel lug nuts should be tightened
according to the following procedure:
²Install the inner wheel to the hub assembly.
²Install the outer wheelMake sure the valve
stems line up with each when aligning the
wheels (Fig. 21).
²Install the cone washers for the outer wheel
before installing the lug nuts (Fig. 22).²Tighten the wheel lug nuts in the numbered
sequential pattern until they are snug tight. Then
tighten lug nuts to specified torque following same
number sequence, (Refer to 22 - TIRES/WHEELS/
WHEELS - SPECIFICATIONS).
²Tighten lug nuts in same numbered sequence a
second time to the specified torque. This will ensure
that the wheels are thoroughly mated.
²Check lug nut specified torque after 100 miles
(160 kilometers). Also after 500 miles (800 kilome-
ters) of vehicle operation.
NOTE: Wheel lug nuts should be tightened to spec-
ified torque at every maintenance interval thereafter.
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the wheel lug studs (SRW) (Fig. 24).
(3) Remove the lug nuts (DRW)On vehicles with
dual rear wheels do not pry off the front hub
cap the lug nuts must be removed in order to
remove the hub cap.(Fig. 23).
Fig. 20 WHEEL RING FLANGE CONE WASHERS
1 - WHEEL STUD
2 - CONE WASHER
Fig. 21 DUAL REAR WHEEL
1 - VALVE STEMS
2 - LUG NUTS
Fig. 22 (DRW) WHEEL CONE WASHERS
1 - CONE WASHER
2 - LUG STUD
22 - 14 TIRES/WHEELSVA