2006 MERCEDES-BENZ SPRINTER differential

(4) Install upper differential side gear (1) and shim
(2) (Fig. 45).
(5) Install differential cover with location numbers
(1) on differential case (2) aligned (Fig. 46).(6) Install differential cover (2) bolts (1) and
tighten to 45 N´m (33 ft. lbs.) (Fig. 47).
(7) Check torque to rotate the differential gears
with Torque Tool 9744 and a torque wrench. Torque
should be 20-40 N´m (15-30 ft. lbs.).
NOTE: Shims are available in 0.05 mm (0.002 in.)
increments, in thicknesses from 1.30 - 2.00 mm
(0.051 - 0.078 in.).
Fig. 45 UPPER SIDE GEAR
1 - SIDE GEAR
2 - SHIM
Fig. 46 LOCATION NUMBERS
1 - NUMBERS
2 - CASE
Fig. 47 DIFFERENTIAL COVER
1 - BOLTS
2 - COVER
VAREAR AXLE 3 - 35

ASSEMBLY - DUAL REAR WHEEL
(1) Install lower differential side gear (1) and shim
(Fig. 48).
(2) Install first differential pinions gears (2) with
spherical washers (3) and cross shaft (1) (Fig. 49).(3) Install upper differential side gear (1) and shim
(2) (Fig. 50).
(4) Install differential cover with location numbers
(1) on differential case (2) aligned (Fig. 51).
Fig. 48 LOWER SIDE GEAR
1 - SIDE GEAR
2 - DIFFERENTIAL CASE
Fig. 49 DIFFERENTIAL PINIONS
1 - CROSS SHAFT
2 - PINION GEAR
3 - WASHER
Fig. 50 UPPER SIDE GEAR
1 - SIDE GEAR
2 - SHIM
Fig. 51 LOCATION NUMBERS
1 - NUMBERS
2 - CASE
3 - 36 REAR AXLEVA

(5) Install differential cover (2) bolts (1) and tighen
to 45 N´m (33 ft. lbs.) (Fig. 52).
INSTALLATION
(1) Spread the differential housing (1).
CAUTION: Never spread over 0.3 mm (0.011 in). If
the housing is over-spread, it could be distorted or
damaged.
(2) Install differential case (2) into the housing (1)
with bearings, cups (3) and shims (Fig. 53).
(3) Loosely install differential bearing cap bolts.(4) Remove spreader (2) and adapters (1) from
housing (Fig. 54).
(5) Tighten bearing cap bolts to 70 N´m (52 ft.
lbs.).
(6) Install axle shafts.
(7) Install differential cover and tighten bolts to 65
N´m (48 ft. lbs.).
(8) Fill differential housing with lubricant.
Fig. 52 DIFFERENTIAL COVER
1 - BOLTS
2 - COVER
Fig. 53 DIFFERENTIAL INSTALLATION
1 - HOUSING
2 - DIFFERENTIAL
3 - DIFFERENTIAL BEARINGS
Fig. 54 SPREADER
1 - ADAPTERS
2 - SPREADER
VAREAR AXLE 3 - 37

BEARINGS - DIFFERENTIAL
CASE
REMOVAL
(1) Remove differential bearings with Puller
C-293-PA (1), Plug C-293-3 (2) and four Adapters
C-293-37 (3) (Fig. 55).
INSTALLATION
(1) Set differential on Plug C-293-3.
(2) Install differential (2) bearings (3) with
Installer 9523 (4) and Handle C-4171 (1) (Fig. 56).
(3) Install differential case in axle.
Fig. 55 CASE BEARING PULLER
1 - PULLER
2 - PLUG
3- ADAPTERS
Fig. 56 DIFFERENTIAL BEARINGS
1 - HANDLE
2 - DIFFERENTIAL
3 - BEARING
4 - INSTALLER
3 - 38 REAR AXLEVA

(13) Connect propeller shaft to pinion flange.
NOTE: On dual rear wheel axle install axle shafts.
(14) Pour in oil up to bottom edge of oil filler hole
(1) (Fig. 63).
(15) Screw in oil filler plug (1) and tighten to 100
N´m (74 ft. lbs.).
(16) Install wheels at rear axle.
(17) Operate brake pedal several times until brake
pads contact brake discs (brake pressure built up).
(18) Attach rear brake cables if removed and
adjust parking brake.
GEAR - PINION / RING
REMOVAL
NOTE: The ring and pinion gears are serviced in a
matched set. Never replace one gear without replac-
ing the other gear.
(1) Remove differential from housing.
(2) Place differential case in a vise with soft metal
jaw.
(3) Remove ring gear bolts from the differential
case.
(4) Drive ring gear off the differential case with a
dead-blow hammer (Fig. 64).(5) Unlock collared nut.
(6) Hold pinion flange with Flange Wrench C-3281
and remove nut.
(7) Remove pinion flange from pinion shaft with
Puller 8892 and Wrench C-3281 (Fig. 65).
(8) Remove pinion gear from housing with a dead-
blow hammer.
(9) Remove pinion shaft seal with a seal pick.
(10) Remove front pinion bearing.
(11) Remove front pinion bearing cup with
Remover D-103 and Handle C-4171.
(12) Remove rear pinion bearing cup with Remover
9084 and Handle C-4171.
(13) Remove pinion depth shim from rear pinion
bearing cup bore.
(14) Remove collapsible spacer (Fig. 66).
Fig. 63 FILL PLUG
1 - FILL PLUG
2 - DRAIN PLUG
Fig. 64 RING GEAR
1 - CASE
2 - RING GEAR
3 - DEAD-BLOW HAMMER
Fig. 65 FLANGE PULLER
1 - FLANGE PULLER
2 - PINION FLANGE
VAREAR AXLE 3 - 41

(14) Bend collar so it touches the wall of the slot
in the pinion shaft (Fig. 74).
(15) Invert differential case and start two ring
gear bolts. This will provide case-to-ring gear bolt
hole alignment.
(16) Invert differential case in the vise and install
new ring gear bolts and alternately tighten to 180
N.m (133 ft. lbs.) (Fig. 75)
CAUTION: Do not reuse ring gear bolts, the bolts
can fracture causing extensive damage. Failure to
heed caution may result in damage.(17) Install differential in axle housing and verify
gear mesh and contact pattern.
Fig. 73 COLLARED NUT
Fig. 74 BEND COLLAR OF NUT
1 - COLLARED NUT
2 - DRIFT
Fig. 75 RING GEAR
1 - TORQUE WRENCH
2 - RING GEAR BOLT
3 - RING GEAR
4 - CASE
3 - 44 REAR AXLEVA

INSTALLATION
(1) Connect separate wheel speed sensor cables
with shrink-fit sleeves and shrink-fit tubing (Fig. 3).
Only do this step if replacing the sensor.
(2) Install the clamping bushing into the knuckle
(Fig. 3)Only do this step if replacing the sensor
or the clamping bushing was damaged.
(3) 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).
(4) Install the rear wheels.
(5) 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).
STEERING ANGLE SENSOR
DESCRIPTION
Fig. 3 REAR WHEEL SPEED SENSORS
1 - SHRINK-FIT SLEEVE
2 - SPEED SENSOR
3 - CLAMPING BUSHING
4 - SHRINK TUBE
Fig. 4 TONE WHEEL REMOVAL
1 - HOOKED PRYBAR
2 - TONE WHEEL
3 - HUB/BEARING ASSEMBLY
Fig. 5 STEERING ANGLE SENSOR
1 - UPPER STEERING COLUMN COVER
2 - CLOCKSPRING
3 - STEERING ANGLE SENSOR
4 - LOWER STEERING COLUMN COVER
5 - FRONT COVER
6 - STEERING ANGLE SENSOR ELECTRICAL CONNECTION
5 - 32 BRAKES - ABSVA

8W-02 COMPONENT INDEX
Component Page
A/C Auxiliary Fan..................... 8W-42
A/C Auxiliary Fan Relay................ 8W-42
A/C Compressor Clutch................. 8W-42
A/C Compressor Clutch Relay............ 8W-42
A/C Roof Auxiliary Fan................. 8W-42
A/C Roof Auxiliary Fan Relay............ 8W-42
Accelerator Pedal Position Sensor......... 8W-30
Additional Heat Exchanger.............. 8W-42
Additional Heat Exchanger Relay......... 8W-42
Additional Heat Exchanger Switch........ 8W-42
Air Outlet Temperature Sensor........... 8W-42
Airbag Control Module................. 8W-43
Airbag Squibs........................ 8W-43
Ambient Temperature Sensor............ 8W-42
Anti Icing Switch..................... 8W-42
Ash Receiver Lamp.................... 8W-44
Automatic Temperature Control Module.... 8W-42
Auxiliary Heater Control................ 8W-42
Battery............................. 8W-20
Battery Relay-Auxiliary................ 8W-20
Battery-Auxiliary..................... 8W-20
Beam Select Switch.................... 8W-50
Blower Motor Resistor Block............. 8W-42
Blower Motor-Front.................... 8W-42
Blower Stage I Diode................... 8W-42
Body Plug Connector................... 8W-11
Boost Pressure Sensor.................. 8W-30
Boost Pressure Servomotor.............. 8W-30
Boost Pressure Solenoid................ 8W-30
Brake Fluid Level Switch............... 8W-35
Brake Lamp Switch.................... 8W-35
Brake Lamp Switch 4 Pole.............. 8W-35
Brake Pressure Sensor................. 8W-35
Brake Wear Sensors................... 8W-35
CTEL Antenna Connector............... 8W-55
CTEL Connector...................... 8W-55
Cabin Heater Assembly................. 8W-42
Cabin Heater Module.................. 8W-42
Camshaft Position Sensor............... 8W-30
Center High Mounted Stop Lamp......... 8W-51
Central Timer Module.................. 8W-45
Cigar Lighter......................... 8W-41
Cigar Lighter Lamp................... 8W-44
Circulation Pump..................... 8W-42
Circulation Pump Diode................ 8W-42
Circulation Pump Relay-Cabin Heater
Module........................... 8W-42
Clockspring....................... 8W-41, 43
Controller Antilock Brake............... 8W-35
Courtesy Lamps...................... 8W-44
Crankcase Heater..................... 8W-30
Crankshaft Position Sensor.............. 8W-30Component Page
Cylinder Lock Switch-Driver............. 8W-61
D+ Relays........................ 8W-10, 11
Data Link Connector................... 8W-18
Daytime Running Lamp Relays........... 8W-50
Differential Lock Solenoid Valve.......... 8W-31
Dome Lamp.......................... 8W-44
Door Jamb Switch-Rear................. 8W-61
Door Jamb Switches................... 8W-44
Door Jamb Switches-Sliding............. 8W-61
Door Lock Motor/Ajar Switch Assemblies . . . 8W-61
Dosing Pump......................... 8W-42
EGR Valve........................... 8W-30
Electrohydraulic Control Unit............ 8W-31
Engine Control Module................. 8W-30
Engine Control Relay.................. 8W-31
Engine Coolant Level Switch............. 8W-30
Engine Coolant Temperature Sensor....... 8W-30
Engine Oil Sensor..................... 8W-30
Evaporator Temperature Sensor.......... 8W-42
Fan Stage 1 Relay..................... 8W-42
Fog Lamp Relay...................... 8W-50
Fog Lamp Switch..................... 8W-50
Fuel Injectors........................ 8W-30
Fuel Level Sensor..................... 8W-30
Fuel Pressure Sensor.................. 8W-30
Fuel Pressure Solenoid................. 8W-30
Fuel Pump........................... 8W-30
Fuel Pump Relay...................... 8W-30
Fuel Quantity Control Valve............. 8W-30
Fuel Shutdown Solenoid................ 8W-30
Fuel Temperature Sensor............... 8W-30
Fuse Blocks.................... 8W-10, 11, 30
Fuse/Relay Block...................... 8W-11
Fused Ignition Switch Run-Start Relay..... 8W-11
Fuses......................... 8W-10, 11, 42
Generator........................... 8W-20
Glow Plug Control Module.............. 8W-30
Glow Plugs.......................... 8W-30
Grounds............................ 8W-15
Hazard Warning Switch................ 8W-52
Headlamp Adjust Switch................ 8W-50
Headlamp Assemblies............... 8W-50, 52
Headlamp Switch..................... 8W-50
Heated Seat Modules.................. 8W-63
Heated Seat Switches.................. 8W-63
Heater Timer-Auxiliary................. 8W-42
High Idle Switch...................... 8W-30
High Pressure Switch.................. 8W-42
Hood Ajar Switch..................... 8W-39
Horn............................... 8W-41
Horn Relay.......................... 8W-41
Horn Switch......................... 8W-41
VA8W-02 COMPONENT INDEX 8W - 02 - 1