2006 MERCEDES-BENZ SPRINTER Service Manual

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Page 1897 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual OPERATION
Signals from the input speed sensors (6, 8) (Fig.
183) are recorded in the transmission control module
(TCM) together with the wheel and engine speeds
and other information and are processed

Page 1898 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual upper and lower side of the crescent (1) to the pres-
sure chamber (6) of the housing. The meshing of the
teeth prevents oil flowing from the delivery side to
the intake side. An external gear (3) is

upper and lower side of the crescent (1) to the pres-
sure chamber (6) of the housing. The meshing of the
teeth prevents oil flowing from the delivery side to
the intake side. An external gear (3) is eccentrically
mounted in the pump housing. The external gear is
driven by the internal gear (4) which is connected to
the torque converter hub.
DISASSEMBLY
(1) Remove pump gears (1 and 2) (Fig. 186) from
pump housing.
(2) Remove the inner oil pump seal (1) (Fig. 187).
(3) Replace the outer oil pump O-ring (2) (Fig.
187).
INSPECTION
Before measuring any oil pump components, per-
form a thorough visual inspection of all the compo-nents. If any sign of scoring, scratches, or other
damage is seen, replace the oil pump as an assembly.
SIDE CLEARANCE
Side clearance is the difference between the thick-
ness of the pump gears and the depth of the pocket
in the pump housing. Side clearance can be mea-
sured by laying a flat plate across the mounting face
of the pump housing, and measuring the distance
between the plate and the gears.
Acceptable side clearance:
²Inner gear: 0.064 mm (0.0025 in) max
²Outer gear: 0.069 mm (0.0027 in) max
TIP CLEARANCE
Tip clearance is the difference between the tip
diameters of the gear teeth and the corresponding
diameters of the pocket in the pump housing.
Tip clearance for the inner gear can be checked by
moving the inner gear into tight mesh (2) (Fig. 188)
with the outer gear as shown. Clearance between the
ID of the crescent feature of the housing and the OD
of the teeth of the inner gear (3) should then me
measured at a point 37 mm from the corner of the
crescent (1) feature, as shown below.
Acceptable tip clearance for inner gear:
²0.85 mm (0.033 in) max
Fig. 186 Oil Pump Gears
1 - OUTER PUMP ROTOR
2 - INNER PUMP ROTOR
Fig. 187 Remove Oil Pump Seals
1 - INNER OIL SEAL
2 - OUTER OIL SEAL
Fig. 188 Oil Pump Measurement
1 - MEASURE 37MM FROM THE CORNER OF CRESCENT
2 - TIGHT MESH HERE
3 - MEASURE TIP CLEARANCE HERE
VAAUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 155

Page 1899 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual ASSEMBLY
(1) Install new inner oil pump seal (1) (Fig. 189)
with Seal Installer 8902-A.
(2) Replace O-ring (2) (Fig. 189).
(3) Lubricate pump gears and place in the pump
housing. Insert pump gear (1)

Page 1900 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual (8) Position Bearing Remover 9082 (1) (Fig. 192)
over the inner race of the output shaft bearing.
(9) Slide the collar (3) (Fig. 193) on the Bearing
Remover 9082 (1) downward over the fingers (3) of
t

Page 1901 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual INSTALLATION
CAUTION: Verify that the geartrain end-play shim is
properly installed over the output shaft and against
the park gear.
(1) Install output shaft bearing in the rear trans-
mission housing

Page 1902 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual (9) Stake the output shaft nut to the output shaft
as follows.Place the Staking Tool 9078 (2) and Driver
Handle C-4171 onto the output shaft.
(10) Rotate the Staking Tool 9078 (2) until the
alignment

(9) Stake the output shaft nut to the output shaft
as follows.Place the Staking Tool 9078 (2) and Driver
Handle C-4171 onto the output shaft.
(10) Rotate the Staking Tool 9078 (2) until the
alignment pin (3) engages the output shaft notch (4)
(Fig. 198).
(11) Press downward on the staking tool (1) until
the staking pin (3) contacts the output shaft nut
flange (2) (Fig. 199).
(12) Strike the Driver handle C-4171 with a suit-
able hammer until the output shaft nut is securely
staked to the output shaft.
(13) Install the propeller shaft (Refer to 3 - DIF-
FERENTIAL & DRIVELINE/PROPELLER SHAFT/
PROPELLER SHAFT - INSTALLATION).
OUTPUT SHAFT SEAL
REMOVAL
(1) Remove the propeller shaft (Refer to 3 - DIF-
FERENTIAL & DRIVELINE/PROPELLER SHAFT/
PROPELLER SHAFT - REMOVAL). Move propeller
shaft to the right and tie up.
(2) Verify that the transmission is in PARK in
order to prepare for the removal of the output shaft
nut.
(3) Remove the nut holding the propeller shaft
flange to the output shaft and remove the flange.
(4) Remove the output shaft seal with suitable
screw and slide hammer.
INSTALLATION
(1) Position the new output shaft seal over the out-
put shaft and against the transmission case.
(2) Use Seal Installer 8902A (1) (Fig. 200) to
install the seal.
(3) Verify that the transmission is in PARK in
order to prepare for the installation of the output
shaft nut.
(4) Install the propeller shaft flange onto the out-
put shaft and install an new flange nut. Tighten the
flange nut to 200 N´m (147.5 ft.lbs.).
(5) Stake the output shaft nut to the output shaft
as follows.Place the Staking Tool 9078 (2) and Driver
Handle C-4171 onto the output shaft.
(6) Rotate the Staking Tool 9078 (2) until the
alignment pin (3) engages the output shaft notch (4)
(Fig. 201).
Fig. 199 Stake Output Shaft Nut
1 - STAKING TOOL 9078
2 - PROPELLER FLANGE
3 - STAKING PIN
Fig. 200 Install the Output Shaft Seal
1 - SEAL INSTALLER 8902A
2 - TRANSMISSION CASE
Fig. 201 Align Staking Tool 9078
1 - PROPELLER SHAFT FLANGE
2 - STAKING TOOL 9078
3 - ALIGNMENT PIN
4 - OUTPUT SHAFT NOTCH
VAAUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 159

Page 1903 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual (7) Press downward on the staking tool until the
staking pin (3) contacts the output shaft nut flange
(2) (Fig. 202).
(8) Strike the Driver handle C-4171 with a suit-
able hammer until the output shaf

Page 1904 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual (5) Disconnect the park lock cable coupling (1)
(Fig. 205) from the shift lever assembly (SLA). Press
locking tab (2) together and push coupling (1) against
the spring force into the SLA, twist throug

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