2006 MERCEDES-BENZ SPRINTER lock

DIAL INDICATOR 9524
INSTALLER 9548
ARBOR DISC 9571
PINION BLOCK 9572
DUMMY BEARING 9573
3 - 22 REAR AXLEVA

SHAFT - AXLE SINGLE REAR WHEEL
REMOVAL-SINGLE REAR WHEEL
(1) Remove wheels.
(2) Detach front brake cable.
(3) Pull ABS sensor (18) together with clamp bush-
ing (19) out of bearing cap (Fig. 6).
(4) Remove brake caliper (16) and disk (10) at rear
axle (14). Attach brake caliper with lines connected
in wheel house.
(5) Remove brake shoes (2) of parking brake.
(6) Remove brake control cable lock.
(7) Remove bearing cap bolts (17) and pull axle
shaft out of axle tube (1) (Fig. 6).
(8) Remove seal/gasket.
Fig. 6 AXLE SHAFT
1 - REAR AXLE 11 - BOLT
2 - BRAKE SHOE 12 - WHEEL BOLT
3 - PRESSURE SPRING 13 - BRAKE ADJUSTER
4 - RETURN SPRING 14 - REAR AXLE SHAFT
5 - RETURN SPRING 15 - GASKET
6 - CABLE LOCK 16 - BRAKE CABLE
7 - PARK BRAKE CABLE 17 - BOLT
8 - LOCKING PIN 18 - ABS SENSOR
9 - BOLT 19 - SENSOR BUSHING
10 - BRAKE DISC
VAREAR AXLE 3 - 23

INSTALLATION - SINGLE REAR WHEEL
(1) Install sealing ring.
(2) Install axle shaft (1) in the axle tube (2) (Fig.
7).
(3) Installnewbearing cap (2) bolts (1) and
tighten to 72 N´m (53 ft. lbs.) (Fig. 8).
NOTE: Tighten bolts diagonally across.
(4) Install brake control cable lock.
(5) Install parking brake shoes.
(6) Install brake disk and calipers.
(7) Coat clamping bush with acid-free grease.
Insert ABS sensor with clamping bush fully into the
mounting hole.
(8) Install front brake cable.(9) Operate brake pedal several times until brake
pads contact brake discs (brake pressure built up).
(10) Install wheels.
BEARING / SEAL - AXLE
REMOVAL
(1) Remove rear axle shaft.
(2) With a punch (2) and hammer straighten bear-
ing (4) nut (1) locking ring (3) (Fig. 9).
(3) Install two wheel mounting bolts into the axle
shaft (1) and clamp in vise. Loosen bearing (4) nut
(2) with Wrench 9279 (3) (Fig. 10).
Fig. 7 AXLE SHAFT AND TUBE
1 - AXLE SHAFT
2 - AXLE TUBE
3 - AXLE BEARINGS
4 - DUST SHIELD
Fig. 8 BEARING CAP BOLTS
1 - BEARING CAP BOLTS
2 - BEARING CAP
3 - AXLE SHAFT FLANGE
Fig. 9 LOCKING RING
1 - BEARING NUT
2 - PUNCH
3 - LOCKING RING
4 - BEARING
Fig. 10 BEARING NUT WRENCH
1 - AXLE SHAFT
2 - BEARING NUT
3 - WRENCH
4 - BEARING
3 - 24 REAR AXLEVA

NOTE: Bearing nut with groove on left rear axle
shaft has a left-hand thread. Bearing nut without
groove on right rear axle shaft has a right-hand
thread.
(4) Remove bearing nut (1) and locking ring (2)
from axle shaft (Fig. 11).
(5) Push Plate 9277 (2) between bearing cover and
axle shaft (1) (Fig. 12).(6) Place axle shaft (1) with plate (3) in a press.
(7) Press axle shaft (1) through the bearing cover
and tapered roller bearings (2) (Fig. 13).
(8) Remove tapered roller bearings (6), sealing ring
(7), dust shield (5) and bearing cover (2) from axle
shaft (1) (Fig. 14).
(9) Remove shaft seal (3) from bearing cover (2)
with a hammer and drift.
Fig. 11 BEARING NUT AND LOCKING RING
1 - BEARING NUT
2 - LOCKING RING
Fig. 12 AXLE BEARING REMOVAL TOOL
1 - AXLE SHAFT
2 - PLATE
Fig. 13 PRESSING BEARING
1 - AXLE SHAFT
2 - BEARING
3 - PLATE
Fig. 14 AXLE SHAFT ASSEMBLY
1 - AXLE SHAFT 6 - BEARING
2 - BEARING COVER 7 - SEALING RING
3 - RADIAL SHAFT SEAL 8 - LOCKING RING
4 - GASKET 9 - BEARING NUT
5 - DUST SHIELD
VAREAR AXLE 3 - 25

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

(9) Screw on bearing nut (1) and tighten nut with
Wrench 9279 to 500 N´m (369 ft. lbs.).
NOTE: Bearing nut with groove on left rear axle
shaft has a left-hand thread. Bearing nut without
groove on right rear axle shaft has a right-hand
thread.
(10) Bend locking ring (3) with a hammer and
punch at both grooves in the bearing nut (Fig. 19).
NOTE: The grooved nut must be locked in both
directions of rotation.
(11) Install sealing ring (4) onto roller bearing race
(Fig. 19).
(12) Install rear axle shaft.
SHAFT - AXLE DUAL REAR
WHEELS
REMOVAL - DUAL REAR WHEEL
(1) Remove wheels
(2) Remove axle shaft (2) hub (1) nuts (3) (Fig. 20).
(3) Pull out axle shaft.
Fig. 19 LOCKING RING
1 - BEARING NUT
2 - BEARING
3 - LOCKING RING
4 - SEALING RING
Fig. 20 AXLE SHAFT
1 - WHEEL HUB
2 - AXLE SHAFT
3 - AXLE NUT
VAREAR AXLE 3 - 27

INSTALLATION - DUAL REAR WHEEL
(1) Coat axle shaft flange with Mopar Metal
Assembly Paste.
(2) Slide axle shaft (2) into axle tube.
(3) Install axle shaft hub (1) nuts (3) and tighten
to N´m 65 (48 ft. lbs.) (Fig. 21).
(4) Install wheels.
BEARING / SEAL - AXLE HUB
REMOVAL
(1) Remove brake caliper with support.
(2) Remove axle shaft.
(3) Back-off parking brakes.
(4) Remove outer hub nut (1) with Wrench 9290
(Fig. 22).
(5) Remove locking plate (2), inner hub nut (1) and
thrust washer (3) (Fig. 22).
CAUTION: Thrust washer is designed for left or
right side and are not interchangeable.
(6) Pull hub off axle tube.
Fig. 21 AXLE SHAFT
1 - WHEEL HUB
2 - AXLE SHAFT
3 - AXLE NUT
Fig. 22 HUB NUTS
1 - NUTS
2 - LOCKING PLATE
3 - THRUST WASHER
3 - 28 REAR AXLEVA

(9) Install outer hub (1) bearing (2) (Fig. 26).
(10) Install thrust washer (2) (Fig. 27).
CAUTION: Thrust washer is designed for left or
right side and are not interchangeable.(11) Install inner hub (1) nut (2) (Fig. 28).
(12) Tighten inner hub nut with Wrench 9290 to
300 N´m (221 ft. lbs.) while spinning the wheel hub
constantly. Turn back inner nut and then tighten
until it touches the thrust washer without play. Then
tighten 1/8 turn.
(13) Install locking plate (2) (Fig. 29).
(14) Install outer hub nut and tighten with
Wrench 9290 to 250 N´m (184 ft. lbs.).
(15) Install axle shaft.
(16) Install brake caliper and support.
(17) Adjust parking brakes.
Fig. 26 OUTER HUB BEARING
1 - HUB
2 - BEARING
Fig. 27 THRUST WASHER
1 - HUB
2 - WASHER
Fig. 28 INNER HUB NUT
1 - HUB
2 - NUT
Fig. 29 LOCKING PLATE
1 - HUB
2 - PLATE
3 - 30 REAR AXLEVA