2006 MERCEDES-BENZ SPRINTER wheel alignment

DRIVELINE VIBRATION
Drive Condition Possible Cause Correction
Propeller Shaft Noise 1) Undercoating or other foreign
material on shaft.1) Clean exterior of shaft and wash
with solvent.
2) Loose U-joint clamp screws. 2) Install new clamps and screws
and tighten to proper torque.
3) Loose or bent U-joint yoke or
excessive runout.3) Install new yoke.
4) Incorrect driveline angularity. 4) Measure and correct driveline
angles.
5) Rear spring center bolt not in
seat.5) Loosen spring u-bolts and seat
center bolt.
6) Worn U-joint bearings. 6) Install new U-joint.
7) Propeller shaft damaged or out
of balance.7) Installl new propeller shaft.
8) Broken rear spring. 8) Install new rear spring.
9) Excessive runout or unbalanced
condition.9) Re-index propeller shaft, test,
and evaluate.
10) Excessive drive pinion gear
shaft runout.10) Re-index propeller shaft and
evaluate.
11) Excessive axle yoke deflection. 11) Inspect and replace yoke if
necessary.
12) Excessive transfer case
runout.12) Inspect and repair as neces-
sary.
Universal Joint Noise 1) Loose U-joint clamp screws. 1) Install new clamps and screws
and tighten to proper torque.
2) Lack of lubrication. 2) Replace as U-joints as neces-
sary.
PROPELLER SHAFT BALANCE
NOTE: Removing and indexing the propeller shaft
180É relative to the yoke may eliminate some vibra-
tions.
If propeller shaft is suspected of being out of bal-
ance, verify with the following procedure:
(1) Place vehicle in netrual.
(2) Raise and support the vehicle by the axles as
level as possible.
(3) Clean all foreign material from propeller shaft
and universal joints.
(4) Inspect propeller shaft for missing balance
weights, broken welds, and bent areas.
NOTE: If propeller shaft is bent, it must be replaced.
(5) Inspect universal joints for wear, properly
installed and correct alignment with the shaft.
(6) Check universal joint clamp screws torque.
(7) Remove wheels and tires. Install wheel lug
nuts to retain the brake drums/rotors.(8) Mark and number propeller shaft six inches
from the pinion yoke end at four positions 90É apart.
(9) Run and accelerate the vehicle until vibration
occurs. Note intensity and speed the vibration
occurred. Stop the engine.
(10) Install a screw clamp at position 1 (Fig. 1).
3 - 2 PROPELLER SHAFTVA

PROPELLER SHAFT
REMOVAL
(1) Secure vehicle to prevent it from rolling.
(2) Make installing reference marks on propeller
shaft (Fig. 6) and (Fig. 7).
(3) Remove retaining bracket bolts (Fig. 8) and
(Fig. 9).
(4) Remove propeller shaft bolts from rear axle
and transmission at the flange.
(5) Remove propeller shaft intermediate bearing
nuts from retaining bracket and bracket for brake
cable.
NOTE: The brake cable bracket is only installed in
vehicles with wheelbase 3550 mm
SPLITTER 1130
INSTALLER 9275
INCLINOMETER 7663
Fig. 6 ALIGNMENT MARKS
1 - ALIGNMENT MARK
2 - BOOT
3 - ALIGNMENT MARK
4 - CENTER BEARING
Fig. 7 ALIGNMENT MARKS 3 PIECE SHAFT
1 - REFERNCE MARK
2 - CENTER SHAFT
3 - REFERENCE MARK
4 - REAR SHAFT
VAPROPELLER SHAFT 3 - 7

(6) Remove shaft from the vehicle.
INSTALLATION
(1) Install propeller shaft intermediate bearing/
bearings to support and tighten nuts to 105 N´m (77
ft. lbs.).
(2) Install propeller shaft intermediate bearing
support/supports to frame floor and tighten bolts to
95 N´m (70 ft. lbs.).
(3) Install propeller shaft intermediate bearing
with retaining bracket and bracket for brake cable.
NOTE: The bracket is only installed on vehicles
with wheelbase 3550 mm.
(4) Install propeller shaft to rear axle and trans-
mission flange with installation marks are aligned.
Tighten bolts to 70 N´m (66 ft. lbs.).
(5) Install retaining bracket and tighten bolts to
100 N´m (74 ft. lbs.).
CENTER BEARING
REMOVAL
(1) Remove propeller shaft.
(2) Mark shafts for installation alignment (Fig.
10).(3) Loosen both collar clamps (Fig. 11).
Fig. 9 3 PIECE PROPELLER SHAFT
1 - FLANGE BOLT 7 - BRACKET
2 - INTERMEDIATE BEARING 8 - RETAINING BRACKET
3 - CENTER SHAFT 9 - BOLT
4 - REAR SHAFT 10 - FRONT SHAFT
5 - REAR AXLE 11 - TRANSMISSION
6 - NUT
Fig. 10 ALIGNMENT MARKS
1 - ALIGNMENT MARK
2 - BOOT
3 - ALIGNMENT MARK
4 - CENTER BEARING
VAPROPELLER SHAFT 3 - 9

(4) Remove the fog lamp switch from the face of
the cluster bezel.
INSTALLATION
WARNING: To avoid personal injury or death, on
vehicles equipped with airbags, disable the supple-
mental restraint system before attempting any
steering wheel, steering column, airbag, seat belt
tensioner, or instrument panel component diagno-
sis or service. Disconnect and isolate the battery
negative (ground) cable, then wait two minutes for
the system capacitor to discharge before perform-
ing further diagnosis or service. This is the only
sure way to disable the supplemental restraint sys-
tem. Failure to take the proper precautions could
result in accidental airbag deployment.
(1) Position the fog lamp switch to the proper
mounting hole on the face of the cluster bezel (Fig.
16).
(2) Using hand pressure, push the fog lamp switch
firmly and evenly into the switch mounting hole of
the cluster bezel until both of the latches on the
switch body are fully engaged.
(3) Reinstall the cluster bezel onto the instrument
panel. (Refer to 23 - BODY/INSTRUMENT PANEL/
CLUSTER BEZEL - INSTALLATION).
(4) Reconnect the battery negative cable.
FRONT LAMP UNIT
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the front grille from the vehicle. (Refer
to 23 - BODY/EXTERIOR/GRILLE - REMOVAL).(3) Remove the two screws that secure the cover at
the inboard side of the front lamp unit (Fig. 18).
(4) Remove the cover from the front lamp unit.
(5) From the engine compartment, disconnect the
vehicle wire harness connector from the connector
receptacle for the front lamp unit.
(6) Remove the four screws that secure the front
lamp unit to the front of the vehicle.
(7) Remove the front lamp unit from the front of
the vehicle.
INSTALLATION
(1) Position the front lamp unit to the front of the
vehicle (Fig. 18).
(2) Install and tighten the four screws that secure
the front lamp unit to the front of the vehicle.
(3) From the engine compartment, reconnect the
vehicle wire harness connector to the connector
receptacle for the front lamp unit.
(4) Position the cover to the front lamp unit.
(5) Install and tighten the two screws that secure
the cover at the inboard side of the front lamp unit.
(6) Reinstall the front grille onto the vehicle.
(Refer to 23 - BODY/EXTERIOR/GRILLE - INSTAL-
LATION).
(7) Reconnect the battery negative cable.
(8) Check and adjust the front lamp alignment as
required. (Refer to 8 - ELECTRICAL/LAMPS/LIGHT-
ING - EXTERIOR/FRONT LAMP UNIT - ADJUST-
MENTS).
Fig. 17 Fog Lamp Switch Remove/Install
1 - FOG LAMP SWITCH
2 - LATCH (2)
3 - CLUSTER BEZEL
Fig. 18 Front Lamp Unit Remove/Install
1 - SCREW (2)
2 - COVER
3 - SCREW (4)
4 - LAMP UNIT
5 - WIRE HARNESS CONNECTOR
VALAMPS/LIGHTING - EXTERIOR 8L - 13

INSTALLATION
NOTE: Thoroughly clean all mating surfaces with
the appropriate solvents to assure that no grease or
oil is present during reassembly.
NOTE: Carefully position the rear main seal/adaptor
evenly onto the assembly sleeve. The rear main oil
seal lip MUST NOT roll over the edge of the tool.
(1) Position the rear main oil seal/adaptor with
assembly sleeve onto the crankshaft so that the
dowel sleeves fit into the guide holes (Fig. 33). Care
must be taken so that the oil pan gasket is not dam-
aged.
(2) Install the rear main seal/adaptor to crankcase
bolts and tighten to 9´Nm (80 lbs.in) (Fig. 33).
(3) Tighten the M6 oil pan bolts to 9N´m (80 lbs
in) and the M8 bolts to 20 N´m (15 lbs ft).
(4) Install the fly wheel and tighten bolts in two
stages (Fig. 33). 45N´m (33 lbs. ft.) then 90É.(5) Install the oil pan drain plug and tighten to
25N´m (18 lbs ft).
(6) Lower the vehicle.
(7) Fill the crankcase with the correct engine oil,
to the proper level. Refer to owners manual for spec-
ifications.
(8) Connect the negative battery cable.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHES.
(9) Start the engine and inspect for leaks.
CRANKSHAFT OIL SEAL -
FRONT
REMOVAL
(1) Disconnect the negative battery cable.
(2) Remove the accessory drive belt.
Fig. 33 REAR MAIN SEAL/ADAPTER
1 - FLYWHEEL
2 - FLYWHEEL BOLTS
3 - SPECIAL TOOL 8944
4 - REAR CRANKSHAFT OIL SEAL
5 - REAR CRANKSHAFT SEAL ADAPTER
6 - CRANKSHAFT
7 - ALIGNMENT DOWELS
8 - REAR CRANKSHAFT SEAL ADAPTER RETAINING BOLT
9 - OIL PAN TO REAR CRANKSHAFT SEAL ADAPTER RETAINING BOLT
9 - 42 ENGINEVA

INSTALLATION
INSTALLATION
NOTE: A flex rod torque wrench must not be used
in order to avoid angle errors when tightening to
degrees.
(1) Align flywheel and inner and outer washers
with straight pin. Tighten bolts in two stages. 45N´m
(33 lbs. ft.) then 90É (Fig. 35).
(2) Remove the retaining lock from the crankshaft/
starter ring gear.
(3) Install transmission (Refer to 21 - TRANSMIS-
SION/TRANSAXLE/AUTOMATIC - W5J400 -
INSTALLATION).
(4) Connect negative battery cable.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS IN OPERATION. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHES.
(5) Start the vehicle.
INSTALLATION - CRANKSHAFT LOCK
(1) Raise and support the vehicle.
(2) Remove the generator wiring harness duct at
the crankcase and set aside.(3) Remove inspection cover (Fig. 36).
(4) Remove the bolts (Fig. 36).
(5) Insert the crankshaft lock #8932 into the
starter ring gear and install the retaining bolts.
Tighten the lock bolts to 9 N´m (80 lbs. in.) (Fig. 36).
Fig. 35 FLYWHEEL ASSEMBLY
1 - SPECIAL TOOL #8932 CRANKSHAFT LOCK
2 - RETAINING BOLTS
3 - ALIGNMENT PIN
4 - WASHER
5 - FLYWHEEL
6 - FLYWHEEL BOLT
9 - 44 ENGINEVA

(18) Install calipers. (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/DISC BRAKE CALIPERS
- INSTALLATION)
(19) Install new tie straps holding wheel speed
sensors and brake pad wear sensors wire harness to
cradle.
(20) Check and align vehicle to specifications.
(Refer to 2 - SUSPENSION/WHEEL ALIGNMENT -
STANDARD PROCEDURE)
REAR CROSSMEMBER -
TRANSMISSION
REMOVAL
(1) Raise and support the vehicle. (Refer to
LUBRICATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE)
(2) Support transmission with a suitable lifting
device.
(3) Remove the bolts/nuts and remove transmis-
sion mount cover. (Fig. 16)
(4) Remove crossmember nuts and crossmember.
INSTALLATION
(1) Install crossmember and install nuts.
(2) Tighten crossmember nut to 45 N´m (33 ft.
lbs.).
(3) Remove transmission support.
(4) Install transmission mount bracket.
(5) Install transmission mount bolts/nuts and
tighten to 45 N´m (33 ft. lbs.).
TRAILER HITCH
REMOVAL
(1) Disconnect and isolate battery negative cable.
(2) Raise and support the vehicle. (Refer to
LUBRICATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE)
(3) Disconnect electrical connector. (Fig. 17)
Fig. 16 TRANSMISSION CROSSMEMBER
1 - TRANSMISSION MOUNT BOLTS (2)
2 - TRANSMISSION MOUNT COVER
3 - TRANSMISSION CROSSMEMBER NUTS (4)
4 - TRANSMISSION MOUNT NUTS (2)
5 - TRANSMISSION SUPPORT
6 - CROSSMEMBER
7 - TRANSMISSION MOUNT
VAFRAME & BUMPERS 13 - 11

INSUFFICIENT ASST. OR POOR RETURN TO CENTER
CONDITION POSSIBLE CAUSE CORRECTION
HARD TURNING OR MOMEN-
TARY INCREASE IN TURNING
EFFORT1. Tire pressure. 1. Adjust tire pressure.
2. Low fluid level. 2. Fill to proper level.
3. Loose belt. 3. Adjust or replace.
4. Low pump pressure. 4. Pressure test and repair as nec-
essary.
5. Internal gear leak. 5. Replace gear.
STEERING WHEEL DOES NOT
WANT TO RETURN TO CENTER
POSITION1. Tire pressure. 1. Adjust tire pressure.
2. Wheel alignment. 2. Align front end.
3. Lack of lubrication. 3. Inspect and lubricate suspension
compnents.
4. High friction in steering gear. 4. Replace gear.
LOOSE STEERING AND VEHICLE LEAD
CONDITION POSSIBLE CAUSE CORRECTION
EXCESSIVE PLAY IN STEERING
WHEEL1. Worn or loose suspension or
steering components.1. Inspect and repair as necessary.
2. Worn or loose wheel bearings. 2. Inspect and repair or adjust
bearings.
3. Steering gear mounting. 3. Tighten gear mounting bolts to
specification.
4. Gear out of adjustment. 4. Replace gear.
5. Worn or loose steering coupler. 5. Inspect and replace as neces-
sary.
VEHICLE PULLS OR LEADS TO
ONE SIDE.1. Tire Pressure. 1. Adjust tire pressure.
2. Radial tire lead. 2. Rotate tires.
3. Brakes dragging. 3. Repair as necessary.
4. Wheel alignment. 4. Align front end.
VASTEERING 19 - 3