2006 MERCEDES-BENZ SPRINTER sensor

INSTALLATION
(1) Install the steering knuckle on the lower ball
joint stud (Fig. 6).
(2) Install the lower ball joint nut (Fig. 6). Tighten
to 280 N´m (206 ft. lbs.)
(3) Install the strut to the steering knuckle (Fig.
6). Tighten to 185 N´m (136 ft. lbs.).
(4) Install the outer tie rod end to the steering
knuckle (Fig. 6) and tighten the nut to 130 N´m (96
ft. lbs.).
(5) Install the ABS sensor by pushing the sensor
all the way into the knuckle and the sensor will self
adjust when the wheel is turned.
(6) Install the hub/bearing (Refer to 2 - SUSPEN-
SION/FRONT/HUB / BEARING - INSTALLATION).
(7) Install the disc brake caliper adapter with the
brake caliper (Refer to 5 - BRAKES/HYDRAULIC/
MECHANICAL/DISC BRAKE CALIPER ADAPTER -
INSTALLATION).
(8) Install the front wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - INSTALLATION).
(9) Lower the vehicle.
(10) Check and set toe if necessary (Refer to 2 -
SUSPENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE).
LOWER BALL JOINT
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the front tire and wheel assembly.
(3) Remove the front strut (Refer to 2 - SUSPEN-
SION/FRONT/STRUT - REMOVAL).(4) Remove the steering knuckle (Refer to 2 - SUS-
PENSION/FRONT/KNUCKLE - REMOVAL).
(5) Remove the lower ball joint using special tool
9294-1 (Driver) with 9294-2 (Reciever) and C-4212±F.
(Fig. 7).
INSTALLATION
(1) Install the ball joint into the lower control arm
using special tool 9294-3 (Installer ring) inserted in
9294-2 (Reciever) and C-4212±F (Fig. 7).
(2) Install the front strut (Refer to 2 - SUSPEN-
SION/FRONT/STRUT - INSTALLATION).
(3) Install the steering knuckle (Refer to 2 - SUS-
PENSION/FRONT/KNUCKLE - INSTALLATION).
(4) Install the tire and wheel assembly (Refer to 22
- TIRES/WHEELS/WHEELS - INSTALLATION).
(5) Lower the vehicle.
(6) Check the front wheel alignment (Refer to 2 -
SUSPENSION/WHEEL ALIGNMENT - SPECIFICA-
TIONS).
LOWER CONTROL ARM
REMOVAL
(1) Insert spring blocks special tool 9288 between
the spring and the spring clamp plates, While the
vehicles wheels are on the ground.
(2) Raise and support the vehicle.
(3) Remove the front wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - REMOVAL).
(4) Remove the disc brake caliper adapter (Refer to
5 - BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - REMOVAL).Hang
the caliper. Do not allow brake hose to support
the caliper weight.
(5) Remove the retaining nut holding the tie rod to
the steering knuckle (Fig. 8).
Fig. 6 STEERING KNUCKLE
1 - STRUT
2 - STRUT BOLT
3 - STEERING KNUCKLE
4 - LOWER BALL JOINT NUT
5 - OUTER TIE ROD END RETAINING NUT
6 - INNER TIE ROD END
7 - LOWER CONTROL ARM
Fig. 7 LOWER BALL JOINT
1 - LOWER CONTROL ARM
2 - LOWER BALL JOINT
2 - 6 FRONTVA

(6) Seperate the tie rod off the steering knuckle
(Fig. 8) using special tool C-3894±A.
NOTE: In order to remove tension from the strut,
Raise the lower control arm approximately 10 mm
with a jack.
(7) Remove the strut bolts from the steering
knuckle (Fig. 8).
(8) Remove the stop plate bolts and rotate the
plate upwards with the stabilizer link attached (Fig.
8).
(9) Lower the lower control arm.
(10) Remove the lower ball joint nut from the
steering knuckle (Fig. 8).
(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 (Fig. 8).
(13) Remove the lower control arm.
INSTALLATION
(1) Install the lower control arm to the frame.
Hand tighten the nuts and bolts.
NOTE: In order to remove tension from the strut,
Raise the lower control arm approximately 10 mm
with a jack.(2) Install the lower ball joint into the steering
knuckle. Tighten to 280 N´m (206 ft. lbs.).
(3) Install the strut bolts to the steering knuckle
(Fig. 8). Tighten to 185 N´m (136 ft. lbs.).
(4) Install the stop plate (Refer to 2 - SUSPEN-
SION/FRONT/SPRING STOP PLATES - INSTALLA-
TION).
(5) Lower the lower control arm.
(6) Attach the tie rod to the steering knuckle (Fig.
8). Tighten the nut to 130 N´m (96 ft. lbs.)
(7) Install the disc brake caliper adapter (Refer to
5 - BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - INSTALLATION)
(Fig. 8).
(8) Install the front tire & wheel assembly (Refer
to 22 - TIRES/WHEELS/WHEELS - INSTALLA-
TION).
(9) Lower the vehicle.
(10) Remove the spring blocks between the spring
and the spring clamp plates, While the vehicles
wheels are on the ground.
(11) Roll the vehicle approximately 1 mm forwards
and the backwards, and rock firmly.
(12) Tighten the lower control arm nuts and bolts
to the frame to 150 N´m (110 ft. lbs.) (Fig. 8).
(13) Apply brake to actuate brake pressure.
SPRING
REMOVAL
(1)To do this next step the vehicle must be
on the ground.Remove the front and rear bolts on
the left and right spring clamp plates (Fig. 9).
(2) Raise and support the vehicle.
(3) Remove the front wheels.
(4) Remove the brake caliper adapter (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - REMOVAL).Do not
allow the caliper to hang by the hose, support
the caliper accordingly.
(5) Remove the ABS sensor from the mounting
bore in the steering knuckle (Fig. 9).
(6) Remove the outer tie rod retaining nut and
separate the tie rod from the knuckle (Fig. 9) using
special tool C-3894±A.
NOTE: In order to remove tension from the strut,
Raise the lower control arm approximately 10 mm
with a jack.
(7) Remove the strut bolts from the steering
knuckle.
(8) Remove both stop plate bolts and rotate the
plates upwards with the stabilizer link attached.
(9) Lower the lower control arm.
(10) Remove the lower ball joint nut from the
steering knuckle.
Fig. 8 LOWER CONTROL ARM
1 - STRUT
2 - LOWER CONTROL ARM BOLT
3 - STOP PLATE BOLT
4 - STOP PLATE
5 - CALIPER ADPTER BOLT
6 - DISC BRAKE CALIPER
7 - LOCKING BOLT
8 - DISC BRAKE ROTOR
9 - OUTER TIE ROD END RETAINING NUT
10 - OUTER TIE ROD END
11 - LOWER BALL JOINT NUT
12 - LOWER BALL JOINT
13 - LOWER CONTROL ARM NUTS
14 - STRUT BOLT
VAFRONT 2 - 7

(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

REMOVAL
Fig. 2 SINGLE REAR WHEEL AXLE
1 - REAR SPRING 12 - WEAR INDICATOR CONNECTOR
2 - U-BRACKET 13 - BRAKE HOSE
3 - PLATE 14 - WHEEL BOLT
4 - NUT 15 - BOLT
5 - BRAKE CABLE 16 - NUT
6 - REAR AXLE 17 - PROPELLER SHAFT
7 - ABL LEVER 18 - BOLT
8 - NUT 19 - ABS SENSOR
9 - SHOCK ABSORBER 20 - SENSOR BUSHING
10 - BOLT 21 - VENT LINE
11 - WEAR INDICATOR CABLE
3 - 14 REAR AXLEVA

(1) Raise and support the vehicle.
(2) Position a suitable lifting device under the axle
and secure axle to device.
(3) Remove wheels and tires.
(4) Unplug wear indicator cable (Fig. 2) and (Fig.
3).
(5) Detach cable connector for brake pad wear
indicator.
(6) Remove ABS sensor and clamp bushing from
mounting bore.
NOTE: The right-hand ABS sensor cable is labeled
at the factory with a white tag.
(7) Remove cable ties from the park brake cables.
Release connection cable of brake pad wear indicator
and ABS sensor cable up to the relay unit of the
parking brake.
(8) Remove brake cables.
(9) Remove hand brake cable at relay unit.(10) Remove bracket for brake cables at rear axle
tube.
(11) Remove stabilizer bar from axle brackets.
(12) Remove shock absorber bolts from rear axle.
(13) Remove ALB lever from rear axle bracket.
(14) Pull vent line of rear axle out of frame.
(15) Remove propeller shaft.
(16) Remove brake calipers.
(17) Remove U-brackets and plates (Fig. 2) and
(Fig. 3).
(18) Remove axle from the vehicle.
Fig. 3 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 - 15

INSTALLATION
Fig. 4 SINGLE REAR WHEEL AXLE
1 - REAR SPRING 12 - WEAR INDICATOR CONNECTOR
2 - U-BRACKET 13 - BRAKE HOSE
3 - PLATE 14 - WHEEL BOLT
4 - NUT 15 - BOLT
5 - BRAKE CABLE 16 - NUT
6 - REAR AXLE 17 - PROPELLER SHAFT
7 - ABL LEVER 18 - BOLT
8 - NUT 19 - ABS SENSOR
9 - SHOCK ABSORBER 20 - SENSOR BUSHING
10 - BOLT 21 - VENT LINE
11 - WEAR INDICATOR CABLE
3 - 16 REAR AXLEVA

(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

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