2006 MERCEDES-BENZ SPRINTER tow

effect panels. If necessary, remove the wheels from
the lifted end of the vehicle and lower the vehicle
closer to the ground, to increase the ground clearance
at the opposite end of the vehicle. Install lug nuts on
wheel attaching studs to retain brake drums.
RAMP ANGLE
If a vehicle with flat-bed towing equipment is used,
the approach ramp angle should not exceed 15
degrees.
TOWING WHEN KEYS ARE NOT AVAILABLE
When the vehicle is locked and keys are not avail-
able, use a flat bed hauler. A Wheel-lift or Sling-type
device can be used provided all the wheels are lifted
off the ground using tow dollies.
MAINTENANCE SCHEDULES
DESCRIPTION
The use of special lubricant additives is not recom-
mended. The use of such additives may affect the
warranty rights. With regard to legal stipulations
concerning emissions control, please note that
engines have to be serviced and adjusted in accor-
dance with special instructions and using special
measuring equipment. Modifications to or interfer-
ence with the emissions control systems are not per-
missible.
MAINTENANCE - WITHOUT ASSYST MAINTE-
NANCE COMPUTER
Maintenance Intervals
²Oil service ±Normal Operationevery 10,000
miles or 16,000 km or 12 months.
²Maintenance service every 30,000 miles or
48,000 km.
Additional work must be carried out at yearly
intervals.
MAINTENANCE - WITH ASSYST MAINTENANCE
COMPUTER
ASSYST provides information on the best possible
timing for maintenance work.
When the next maintenance service is due, this
will be indicated in the multi-function display with
the wrench icon symbol displayed in km/miles or
days.
²One wrench icon showing indicates Oil Service
is necessary.
²Two wrench icons showing indicates Mainte-
nance Service is necessary ± displayed in km/miles or
days.
If the display shows the number of days, a clock
symbol will also appear in the multi-function display.You should have the maintenance performed
within the stated period/distance.
The service indicator will be reset after an oil ser-
vice and/or maintenance service has been performed.
REGULAR CHECK - UPS
To maintain the safe operation of the vehicle, it is
recommended that the following tasks be performed
on a regular basis (i.e. weekly or whenever the vehi-
cle is refueled). Check:
²Engine oil level
²Brake system - fluid level
²Battery - acid level
²Windshield washer system and headlamp clean-
ing system - fluid level
²Mechanical assemblies (e.g. engine, transmis-
sion, etc.) - check for leaks
²Condition of tires and tires pressures
²All exterior lights
SPECIAL MAINTENANCE REQUIREMENTS
If bodies built by manufacturers other than
DaimlerChrysler Corporation are fitted to the vehi-
cle, the maintenance requirements and lubrication
intervals specified by the body manufacturer must be
adhered to, in addition to all standard maintenance
requirements.
Coolant
Corrosion inhibitor/antifreeze concentration in the
coolant should be checked before the onset of winter
(once year in countries with high prevailing temper-
atures).
Replace the coolant every five years or 100,000
miles.
Dust Filter for Heating / Ventilation Replacement
The dust filter and the tailgate interior filter are to
be renewed during routine maintenance service. If
operating conditions are dusty, these filters should be
renewed more frequently.
ENGINE OIL CHANGE AND FILTER REPLACEMENT
At a minimum, change the engine oil and oil filter
once a year ± even if the vehicle mileage per year is
extremely low. For standard oil service schedules
refer to the chapter oil service and maintenance ser-
vice.
Once a Year
Select the viscosity of the engine oil (SAE classes)
according to the outside air temperature.
Only use engine oil approved by DaimlerChrysler
Corporation if following the ASSYST system guide-
lines.
0 - 8 LUBRICATION & MAINTENANCEVA

SCOPE OF WORK FOR MAINTENANCE SERVICE
Oil Service
²Engine: Oil change and filter replacement
Check fluid levels of the following system, refill as neces-
sary.
²If fluid is lost, trace and eliminate cause - as a
separate order.
²Power-assisted steering
Lubrication work:
²Trailer tow hitch (original equipment)
Maintenance
²ASSYST maintenance computer reset
Function check
²Signalling system, warning and indicator lamps
²Headlamps, exterior lighting
²Windshield wipers, windshield washer system
Check for leaks and damage
²Check for abrasion points and ensure that lines
are correctly routed!
²All lines and hoses, sensor cables
²Rubber boots on front axle drive shafts, rubber
boots on front axle suspension ball joints, shock
absorbers
²Check fluid levels for the following systems, cor-
rect as necessary
NOTE: Should there be a loss of fluid which cannot
be explained by regular use, trace and eliminate the
cause.
²Engine cooling system. Check corrosion inhibi-
tor/antifreeze, refill as necessary.
²Hydraulic brake system
²Battery
²Windshield washer system
Engine
²Fuel filter renewal - Every oil service
²Air cleaner with maintenance indicator:
²Check degree of contamination.
²Air cleaner filter element renewed as necessary.
Chassis and body
²Trailer coupling: Check operation, play and
retaining fixtures
²Secondary rubber springs: Visual check
²Tire pressures: Correct as necessary, including
spare tire
²Check thickness of brake pads
²Brake test
²Check condition of steering mechanism
²Heating/ventilation dust filter renewal
ADDITIONAL MAINTENANCE WORK
Automatic transmission once only at 80,000 miles / 128000
km
²Oil and filter change
During every second maintenance service
²Air cleaner without maintenance indicator:
²Air cleaner filter element renewal
²Check poly-V-belt for wear and signs of damage
During every fourth maintenance service
²Change rear axle fluid
ADDITIONAL MAINTENANCE WORK AFTER YEARS
Every 2 years
²Change brake fluid.
Every 3 years
²Air cleaner filter element renewal (note installa-
tion date)
Every 15 years or 100,000 miles
²Coolant renewal
²Note coolant composition
INTERNATIONAL SYMBOLS
DESCRIPTION
DaimlerChrysler Corporation uses international
symbols to identify engine compartment lubricant
and fluid inspection and fill locations (Fig. 3).
Fig. 3 INTERNATIONAL SYMBOLS
VALUBRICATION & MAINTENANCE 0 - 9

INSTALLATION
(1) Install the wheel hub with the tapered roller
bearing on the stub axle (Fig. 4).
(2) Grease the outer tapered roller bearing thor-
oughly and push onto the steering knuckle (Fig. 4).
NOTE: The smooth side of the thrust washer must
point toward the wheel bearing.
(3) Install the thrust washer (Fig. 4).
(4) Install the clamping nut (Fig. 4). Tighten to 12
N´m (9 ft. lbs.) and then loosen a half of a turn.
(5) Check for wheel bearing end play. End play
should be 0.02- 0.04 mm (0.000787 - 0.00158 in.)
(Fig. 3) (Refer to 2 - SUSPENSION/FRONT/HUB /
BEARING - DIAGNOSIS AND TESTING).
(6) Pack the grease cap half with grease and coat
at the edge with sealant and install the cap (Fig. 4).
(7) Install the disc brake rotor (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
INSTALLATION).
(8) Install the disc brake caliper adapter (Refer to
5 - BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - INSTALLATION).
(9) Install the wheel flange ring (if equipped with
dual rear wheels) (Fig. 5).
(10) Install the front tire & wheels assembly
(Refer to 22 - TIRES/WHEELS/WHEELS - INSTAL-
LATION).
(11) Lower the vehicle.
KNUCKLE
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the front wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - REMOVAL).
(3) Remove the disc brake caliper adapter (Refer to
5 - BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - REMOVAL).
(4) Remove the hub/bearing (Refer to 2 - SUSPEN-
SION/FRONT/HUB / BEARING - REMOVAL).
(5) Separate the outer tie rod from the steering
knuckle (Fig. 6) using special tool C-3894±A.
(6) Raise the lower control arm approximately 10
mm using a jack.In order to eliminate tensile
force in the damper strut.
(7) Remove the ABS sensor from the knuckle by
pulling straight out.
(8) Remove the strut at the knuckle (Fig. 6).
(9) Separate the lower ball joint from the steering
knuckle using special tool 9282 (Fig. 6).
(10) Remove the steering knuckle from the vehicle
(Fig. 6).
Fig. 4 FRONT WHEEL HUB WITH SINGLE REAR
WHEELS (SRW)
1 - CALIPER ADAPTER BOLT
2 - DISC BRAKE CALIPER
3 - INNER BEARING
4 - WHEEL HUB
5 - DISC BRAKE ROTOR
6 - OUTER BEARING
7 - THRUST WASHER
8 - CLAMPING NUT
9 - GREASE CAP
10 - LOCKING BOLT
11 - GREASE SEAL
12 - STEERING KNUCKLE
Fig. 5 FRONT WHEEL HUB WITH DUAL REAR
WHEELS (DRW)
1 - ADAPTER BOLT
2 - DISC BRAKE CALIPER
3 - INNER BEARING RACE
4 - WHEEL HUB
5 - DISC BRAKE ROTOR
6 - LOCKING BOLT
7 - WHEEL FLANGE RING
8 - OUTER BEARING
9 - THRUST WASHER
10 - CLAMPING NUT
11 - GREASE CAP
12 - WHEEL FLANGE RING MOUNTING BOLT
13 - GREASE SEAL
14 - STEERING KNUCKLE
VAFRONT 2 - 5

(11) Separate the lower ball joint from the knuckle
using special tool 9282.
(12) Remove the lower control arm nuts and bolts
from the frame.
(13) Remove the lower control arm from the frame
(Fig. 9).
NOTE: To avoid damaging the transverse leaf
spring, cushion the pad on the jack accordingly.
(14) Support the transverse leaf spring in the cen-
ter with a jack.
(15) Remove the left and right spring clamp plates
(Refer to 2 - SUSPENSION/FRONT/SPRING CLAMP
PLATES - REMOVAL) (Fig. 9).
NOTE: The upper spring blocks between the engine
cradle and the spring are color coded, Make sure
not to mix the blocks per sides. The blocks are dif-
ferent in sizes to accommodate the weight of the
vehicle and driver in order for the vehicle to sit
level.
(16) Lower the jack and remove the transverse leaf
spring towards the side.INSTALLATION
NOTE: To avoid damaging the transverse leaf
spring, cushion the pad on the jack accordingly.
NOTE: Hand tighten all bolts until vehicle is on the
ground, unless the bushings may become distorted.
NOTE: The height blocks between the engine cradle
and the spring are color coded, Make sure not to
mix the blocks per sides. The blocks are different in
sizes to accommodate the weight of the vehicle and
driver in order for the vehicle to sit level.
(1) Install the transverse leaf spring in the center
with a jack with all the rubber mounts attached.
(2) Install the lower control arm to the frame (Fig.
9).
(3) Install the knuckle on the lower ball joint.
(4) Raise the lower control arm approximately 10
mm with a jack.
(5) Install both stop plate bolts to the lower control
arm
(6) Install the strut bolts to the steering knuckle.
(7) Reinstall the tie rod to the steering knuckle
(Fig. 9). Tighten to 150 N´m (110 ft. lbs.).
(8) Install the ABS sensor all the way into the
steering knuckle, the sensor will adjust automatically
when the vehicle is moved (Fig. 9).
(9) Install the disc brake caliper adapter (Fig. 9).
Tighten to 170 N´m (125 ft. lbs.).
(10) Install the front wheels.
(11) Lower the vehicle.
(12) Install the spring clamp plates (Fig. 9).
Tighten (M-10 bolts) to 65 N´m (48 ft. lbs.) (M-12
bolts) to 130 N´m (96 ft. lbs.).
(13) Roll the vehicle approximately 1 mm forwards
and the backwards, and rock firmly.
(14) Tighten the nuts on the lower control arm to
the frame to 150 N´m (110 ft. lbs.).
(15) Apply brake to actuate brake pressure.
SPRING CLAMP PLATES
REMOVAL
(1) Raise and support the vehicle.
(2) Install a jack under the lower ball joint and
lower the weight of the vehicle enough to allow a
wrench between the lower control arm and the
bracket tighten the nut.
(3) Remove the front and rear bolts to the spring
clamp plates.
(4) Remove the four inner retaining bolts and
nuts.
Fig. 9 FRONT SPRING
1 - NUT
2 - STRUT
3 - STOP PLATE
4 - STOP PLATE BOLT
5 - CALIPER ADAPTER BOLT
6 - DISC BRAKE CALIPER
7 - OUTER TIE ROD END NUT
8 - ABS SENSOR
9 - SPEED SENSOR
10 - LOWER CONTROL ARM RETAINING NUTS
11 - OUTER TIE ROD END
12 - RUBBER SPRING MOUNT
13 - SHEAR BUSHING
14 - SPRING CLAMP PLATE BOLT
15 - SPRING CLAMP PLATE
16 - LOWER RUBBER SPRING MOUNT
17 - SPRING
18 - STRUT BOLTS
19 - LOWER CONTROL ARM BOLTS
2 - 8 FRONTVA

SPRING
DESCRIPTION
The rear suspension system uses a multi-leaf
springs and a solid drive axle. The forward end of the
springs are mounted to the body rail hangers
through rubber bushings. The rearward end of the
springs are attached to the body by the use of shack-
les. The spring and shackles use rubber bushings.
OPERATION
The springs control ride quality and maintain vehi-
cle ride height. The shackles allow the springs to
change their length as the vehicle moves over various
road conditions.
REMOVAL
REMOVAL - (SRW)
(1) Raise and support the vehicle.
(2) Support the rear axle.
(3) Remove the U-bolt and spring plate (Fig. 2).
(4) Remove the spring from the front spring
bracket (Fig. 2).
(5) Remove the rear spring with the spring shackle
from the spring bracket (Fig. 2).
(6) Lower the rear axle and remove the rear
spring.
(7) Remove the spring shackle from the spring (if
needed) (Fig. 2).
REMOVAL - (DRW)
(1) Raise and support the vehicle.
(2) Support the rear axle.
(3) Remove the U-bolt and spring plate (Fig. 3).
(4) Remove the spring from the front spring
bracket (Fig. 3).
(5) Remove the rear spring with the spring shackle
from the spring bracket (Fig. 3).
(6) Lower the rear axle and remove the rear
spring.
(7) Remove the spring shackle from the spring (if
needed) (Fig. 3).
INSTALLATION
INSTALLATION - (SRW)
NOTE: Larger spring bushing goes toward the front.
(1) Install the spring shackle to the spring (if
removed) (Fig. 2). Tighten to 90 N´m (66 ft. lbs.).
(2) Install the spring to the front spring bracket
(Fig. 2). Tighten to 95 N´m (70 ft. lbs.).
(3) Install the spring to the rear spring bracket
(Fig. 2). Tighten to 85 N´m (63 ft. lbs.).
(4) Raise the rear axle and attach the spring plate
and U-bolts (Fig. 2). Tighten to 170 N´m (125 ft. lbs.).
(5) Lower the vehicle.
Fig. 2 REAR LEAF SPRING WITH SINGLE REAR
WHEELS
1 - NUT
2 - LEAF SPRING
3 - U-BOLTS
4 - PLATE
5 - SPRING BOLT
6 - SHACKLE BOLT
7 - SPRING SHACKLE
8 - U-BOLT NUTS
Fig. 3 REAR LEAF SPRING WITH DUAL REAR
WHEELS
1 - U-BOLTS
2 - NUT
3 - BOLT
4 - SPRING SHACKLE
5 - U-BOLT MOUNTING NUT
6 - U-BOLT BRACKET ALIGNING PLATE
7 - LEAF SPRING
2 - 14 REARVA

INSTALLATION - (DRW)
NOTE: Larger spring bushing goes toward the front.
(1) Install the spring shackle to the spring (if
removed) (Fig. 3). Tighten to 185 N´m (136 ft. lbs.).
(2) Install the spring to the front spring bracket
(Fig. 3). Tighten to 185 N´m (136 ft. lbs.).
(3) Install the spring to the rear spring bracket
(Fig. 3). Tighten to 185 N´m (136 ft. lbs.).
(4) Raise the rear axle and attach the spring plate
and U-bolts (Fig. 3). Tighten to 170 N´m (125 ft. lbs.).
(5) Lower the vehicle.
SPRING SHACKLE
REMOVAL
(1) Raise and support the vehicle.
(2) Support the rear axle.
(3) Remove both the rear spring shackles from the
spring bracket.
(4) Lower the rear axle and remove the rear spring
shackle from the spring.
INSTALLATION
(1) Install the spring shackle to the spring.
Tighten to 90 N´m (66 ft. lbs.).
(2) Raise the rear axle while installing the spring
shackle to the spring bracket. Tighten to 85 N´m (63
ft. lbs.).
(3) Lower the vehicle.
STABILIZER BAR
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the stabilizer links at the bar (Fig. 4).
(3) Remove the stabilizer bar clamp at the axle
(Fig. 4).
(4) Remove the bracket (Fig. 4)
(5) Remove the stabilizer bar from the vehicle.
INSTALLATION
(1) Install the stabilizer bar to the axle.
(2) Install the stabilizer bar clamps and bracket,
center the bar then tighten to 25 N´m (18ft. lbs.)
(SRW) (Fig. 4) or Tighten to 70 N´m (52 ft. lbs.) for
(DRW) (Fig. 5).
(3) Install the stabilizer bar to the stabilizer links
and tighten to 95 N´m (60 ft. lbs.) (Fig. 4) or (Fig. 5).
(4) Lower the vehicle.
Fig. 4 SWAY BAR WITH SINGLE REAR WHEELS
(SRW)
1 - M12 NUT
2 - BUSHING
3 - SWAY BAR LINK
4 - M12 BOLT
5-SWAYBAR
6 - CLAMP
7-M8BOLT
8 - BRACKET
9 - FOUR POINT NUT M8
10 - WASHER
11-M8NUT
12 - BUSHING
13 - MOUNT
VAREAR 2 - 15

(1) Raise axle into position.
(2) Install plates and U-brackets (Fig. 4) and (Fig.
5) 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.
(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.
Fig. 5 DUAL REAR WHEEL AXLE
1 - SPRING 12 - BRAKE HOSE
2 - SPRING SHACKLE 13 - LUG NUT
3 - PLATE 14 - NUT
4 - COLLAR NUT 15 - WASHER
5 - BRAKE CABLE 16 - BOLT
6 - REAR AXLE 17 - SHOCK ABSORBER
7 - ALB LEVER 18 - PROPELLER SHAFT
8 - NUT 19 - BOLT
9 - BOLT 20 - ABS SENSOR
10 - WEAR INDICATOR CABLE 21 - SENSOR BUSHING
11 - WEAR INDICATOR CONNECTOR
VAREAR AXLE 3 - 17

INSTALLATION
(1) Clean sealing surface of bearing cap.
(2) Install axle shaft seal into bearing cover (1)
with Installer 9278 (2) (Fig. 15).
NOTE: Install flush to a max. 3 mm (0.12 in.) deep
inside the bearing cover.
(3) Check roller bearing (1), and replace if neces-
sary.
NOTE: Thoroughly grease roller bearings prior to
installation with Mopar High Temp Light Bearing
Grease.
(4) Install bearing cover with axle shaft seal,new
gasket and dust shield on the axle shaft.
(5) Install tapered roller bearings (1) and race (2)
on the axle shaft (Fig. 16).(6) Installnewlocking ring (1) on axle shaft (2).
NOTE: The flat side of the locking ring must point
towards the nut (Fig. 17). The locking ring is fitted
to ensure the pressing is done over the inner bear-
ing race only. The flat on the locking ring must be
aligned with the flat on the axle shaft otherwise the
axle shaft will be damaged.
(7) Place axle shaft (2) through the hole in Plate
9277 (3) and position the assembly in a press (1)
(Fig. 18).
(8) Press tapered roller bearing onto rear axle
shaft as far as the stop.
CAUTION: In order to avoid damaging the bearing,
the outer race must be turned while pressing on.
Fig. 15 SEAL INSTALLER
1 - INSTALLER
2 - BEARING COVER
Fig. 16 BEARINGS AND RACE
1 - BEARINGS
2 - RACE
Fig. 17 BEARING AND SHAFT
1 - LOCKING RING
2 - AXLE SHAFT
3 - BEARING
4 - DUST SHIELD
Fig. 18 PRESSING AXLE SHAFT
1 - PRESS
2 - AXLE SHAFT
3 - PLATE
3 - 26 REAR AXLEVA