2006 MERCEDES-BENZ SPRINTER Service Manual

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Page 785 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual INSTALLATION
(1) Pack space between dust lip and sealing lip on
seal ring with multi-purpose grease.
(2) On seals without rubberized external surface,
coat outer circumference with sealant.
CAUTION: D

Page 786 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual (13) Connect propeller shaft to pinion flange.
NOTE: On dual rear wheel axle install axle shafts.
(14) Pour in oil up to bottom edge of oil filler hole
(1) (Fig. 63).
(15) Screw in oil filler plug (1)

Page 787 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual (15) Remove spacer from pinion shaft (Fig. 67).
(16) Remove rear bearing from pinion shaft with
Puller/Press C-293-PA and Adapters C-293-47 (Fig.
68).
INSTALLATION
(1) Apply Mopar Door Ease or equival

Page 788 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual (6) Install pinion spacer on pinion shaft (Fig.
70).
(7) Installnewcollapsible preload spacer on pin-
ion shaft (Fig. 71) and install pinion gear into the
housing.(8) Install front pinion bearing into

Page 789 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual (14) Bend collar so it touches the wall of the slot
in the pinion shaft (Fig. 74).
(15) Invert differential case and start two ring
gear bolts. This will provide case-to-ring gear bolt
hole alignment.

Page 790 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual BRAKES
TABLE OF CONTENTS
page page
BRAKES - BASE........................... 1BRAKES - ABS........................... 30
BRAKES - BASE
TABLE OF CONTENTS
page page
BRAKES - BASE
DIAGNOSIS AND TESTING -

BRAKES
TABLE OF CONTENTS
page page
BRAKES - BASE........................... 1BRAKES - ABS........................... 30
BRAKES - BASE
TABLE OF CONTENTS
page page
BRAKES - BASE
DIAGNOSIS AND TESTING - BASE BRAKE
SYSTEM.............................2
STANDARD PROCEDURE
STANDARD PROCEDURE - MANUAL
BLEEDING............................4
STANDARD PROCEDURE - PRESSURE
BLEEDING............................5
HYDRAULIC/MECHANICAL
SPECIFICATIONS
SPECIFICATIONS - TORQUE CHART.......5
BASE BRAKE.........................6
SPECIAL TOOLS
BRAKES.............................7
BRAKE LINES
STANDARD PROCEDURE
STANDARD PROCEDURE - ISO FLARING . . . 8
STANDARD PROCEDURE - DOUBLE
INVERTED FLARING....................8
BRAKE PADS/SHOES
REMOVAL
REMOVAL - FRONT (SRW)...............8
REMOVAL - FRONT (DRW)...............9
REMOVAL - REAR (16º WHEELS) (SRW)....9
REMOVAL - REAR (15º WHEELS) (SRW) . . . 10
REMOVAL - REAR (DRW)...............10
INSTALLATION
INSTALLATION - FRONT (SRW)...........11
INSTALLATION - FRONT (DRW)..........11
INSTALLATION - REAR (16º WHEELS)
(SRW) ..............................11
INSTALLATION - REAR (16º WHEELS)
(SRW) ..............................11
INSTALLATION - REAR (DRW)...........11
DISC BRAKE CALIPERS
REMOVAL
REMOVAL - FRONT (SRW)..............11
REMOVAL - FRONT (DRW)..............12
REMOVAL - REAR (SRW)...............12
REMOVAL - REAR (DRW)...............13INSTALLATION
INSTALLATION - FRONT (SRW)..........13
INSTALLATION - FRONT (DRW)..........13
INSTALLATION - REAR (SRW)...........14
INSTALLATION - REAR (DRW)...........14
DISC BRAKE CALIPER ADAPTER
REMOVAL
REMOVAL - FRONT....................14
REMOVAL - REAR.....................14
INSTALLATION
INSTALLATION - FRONT................14
INSTALLATION - REAR.................14
FLUID
DIAGNOSIS AND TESTING - BRAKE FLUID
CONTAMINATION.....................15
STANDARD PROCEDURE - BRAKE FLUID
LEVEL..............................15
SPECIFICATIONS
BRAKE FLUID........................15
FLUID RESERVOIR
REMOVAL.............................15
INSTALLATION.........................15
ALB LEVER
REMOVAL.............................16
INSTALLATION.........................16
ALB CONTROLLER
REMOVAL.............................16
INSTALLATION.........................16
ADJUSTMENTS
ADJUSTMENT........................16
MASTER CYLINDER
DIAGNOSIS AND TESTING - MASTER
CYLINDER/POWER BOOSTER...........17
STANDARD PROCEDURE - MASTER
CYLINDER BLEEDING..................18
REMOVAL.............................18
INSTALLATION.........................19
PEDAL
REMOVAL.............................19
INSTALLATION.........................19
VABRAKES 5 - 1

Page 791 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual POWER BRAKE BOOSTER
DESCRIPTION.........................19
OPERATION...........................19
REMOVAL.............................20
INSTALLATION.........................20
ROTORS
REMOVAL
REMOVAL

POWER BRAKE BOOSTER
DESCRIPTION.........................19
OPERATION...........................19
REMOVAL.............................20
INSTALLATION.........................20
ROTORS
REMOVAL
REMOVAL - FRONT (SRW)..............20
REMOVAL - REAR (SRW)...............20
REMOVAL - FRONT (DRW)..............21
REMOVAL - REAR (DRW)...............21
INSTALLATION
INSTALLATION - FRONT (SRW)..........22
INSTALLATION - REAR (SRW)...........22
INSTALLATION - FRONT (DRW)..........22
INSTALLATION - REAR (DRW)...........22
SUPPORT PLATE
REMOVAL - REAR......................23
INSTALLATION - REAR...................23
PARKING BRAKE
SPECIFICATIONS
TORQUE CHART......................23
SPECIAL TOOLS
PARK BRAKE........................24
CABLE TENSIONER
REMOVAL.............................24INSTALLATION.........................24
CABLES
REMOVAL
REMOVAL - FRONT....................24
REMOVAL - REAR.....................25
INSTALLATION
INSTALLATION - FRONT................25
INSTALLATION - REAR.................26
ADJUSTMENTS
ADJUSTMENT - PARKING BRAKE CABLES . 26
LEVER
REMOVAL.............................26
INSTALLATION.........................27
SHOES
REMOVAL
REMOVAL - (SRW)....................27
REMOVAL - (DRW)....................27
CLEANING - REAR DRUM IN HAT BRAKE....28
INSTALLATION
INSTALLATION - (SRW).................28
INSTALLATION - (DRW).................28
ADJUSTMENTS
ADJUSTMENT........................28
BRAKES - BASE
DIAGNOSIS AND TESTING - BASE BRAKE SYS-
TEM
Base brake components consist of the brake pads,
calipers, brake drum in hat rotor in the rear, rotors,
brake lines, master cylinder, booster, and parking
brake components.
Brake diagnosis involves determining if the prob-
lem is related to a mechanical, hydraulic, or vacuum
operated component.
The first diagnosis step is the preliminary check.
PRELIMINARY BRAKE CHECK
(1) Check condition of tires and wheels. Damaged
wheels and worn, damaged, or underinflated tires
can cause pull, shudder, vibration, and a condition
similar to grab.
(2) If complaint was based on noise when braking,
check suspension components. Jounce front and rear
of vehicle and listen for noise that might be caused
by loose, worn or damaged suspension or steering
components.
(3) Inspect brake fluid level and condition. Note
that the brake reservoir fluid level will decrease in
proportion to normal lining wear.Also note that
brake fluid tends to darken over time. This is
normal and should not be mistaken for contam-
ination.(a) If fluid level is abnormally low, look for evi-
dence of leaks at calipers, wheel cylinders, brake
lines, and master cylinder.
(b) If fluid appears contaminated, drain out a
sample to examine. System will have to be flushed
if fluid is separated into layers, or contains a sub-
stance other than brake fluid. The system seals
and cups will also have to be replaced after flush-
ing. Use clean brake fluid to flush the system.
(4) Check parking brake operation. Verify free
movement and full release of cables and pedal. Also
note if vehicle was being operated with parking
brake partially applied.
(5) Check brake pedal operation. Verify that pedal
does not bind and has adequate free play. If pedal
lacks free play, check pedal and power booster for
being loose or for bind condition. Do not road test
until condition is corrected.
(6) Check booster vacuum check valve and hose.
(7) If components checked appear OK, road test
the vehicle.
ROAD TESTING
(1) If complaint involved low brake pedal, pump
pedal and note if it comes back up to normal height.
(2) Check brake pedal response with transmission
in Neutral and engine running. Pedal should remain
firm under constant foot pressure.
5 - 2 BRAKES - BASEVA

Page 792 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual (3) During road test, make normal and firm brake
stops in 25-40 mph range. Note faulty brake opera-
tion such as low pedal, hard pedal, fade, pedal pulsa-
tion, pull, grab, drag, noise, etc.
(4) Attem

(3) During road test, make normal and firm brake
stops in 25-40 mph range. Note faulty brake opera-
tion such as low pedal, hard pedal, fade, pedal pulsa-
tion, pull, grab, drag, noise, etc.
(4) Attempt to stop the vehicle with the parking
brake only and note grab, drag, noise, etc.
PEDAL FALLS AWAY
A brake pedal that falls away under steady foot
pressure is generally the result of a system leak. The
leak point could be at a brake line, fitting, hose, or
caliper/wheel cylinder. If leakage is severe, fluid will
be evident at or around the leaking component.
Internal leakage (seal by-pass) in the master cylin-
der caused by worn or damaged piston cups, may
also be the problem cause.
An internal leak in the ABS or RWAL system may
also be the problem with no physical evidence.
LOW PEDAL
If a low pedal is experienced, pump the pedal sev-
eral times. If the pedal comes back up worn linings,
rotors, drums, or rear brakes out of adjustment are
the most likely causes. The proper course of action is
to inspect and replace all worn component and make
the proper adjustments.
SPONGY PEDAL
A spongy pedal is most often caused by air in the
system. However, thin brake drums or substandard
brake lines and hoses can also cause a spongy pedal.
The proper course of action is to bleed the system,
and replace thin drums and substandard quality
brake hoses if suspected.
HARD PEDAL OR HIGH PEDAL EFFORT
A hard pedal or high pedal effort may be due to
lining that is water soaked, contaminated, glazed, or
badly worn. The power booster or check valve could
also be faulty.
PEDAL PULSATION
Pedal pulsation is caused by components that are
loose, or beyond tolerance limits.
The primary cause of pulsation are disc brake
rotors with excessive lateral runout or thickness vari-
ation, or out of round brake drums. Other causes are
loose wheel bearings or calipers and worn, damaged
tires.
NOTE: Some pedal pulsation may be felt during
ABS activation.
BRAKE DRAG
Brake drag occurs when the lining is in constant
contact with the rotor or drum. Drag can occur at one
wheel, all wheels, fronts only, or rears only.Drag is a product of incomplete brake shoe release.
Drag can be minor or severe enough to overheat the
linings, rotors and drums.
Minor drag will usually cause slight surface char-
ring of the lining. It can also generate hard spots in
rotors and drums from the overheat-cool down pro-
cess. In most cases, the rotors, drums, wheels and
tires are quite warm to the touch after the vehicle is
stopped.
Severe drag can char the brake lining all the way
through. It can also distort and score rotors and
drums to the point of replacement. The wheels, tires
and brake components will be extremely hot. In
severe cases, the lining may generate smoke as it
chars from overheating.
Common causes of brake drag are:
²Seized or improperly adjusted parking brake
cables.
²Loose/worn wheel bearing.
²Seized caliper or wheel cylinder piston.
²Caliper binding on corroded bushings or rusted
slide surfaces.
²Loose caliper mounting.
²Drum brake shoes binding on worn/damaged
support plates.
²Mis-assembled components.
²Long booster output rod.
If brake drag occurs at all wheels, the problem
may be related to a blocked master cylinder return
port, or faulty power booster (binds-does not release).
BRAKE FADE
Brake fade is usually a product of overheating
caused by brake drag. However, brake overheating
and resulting fade can also be caused by riding the
brake pedal, making repeated high deceleration stops
in a short time span, or constant braking on steep
mountain roads. Refer to the Brake Drag information
in this section for causes.
BRAKE PULL
Front brake pull condition could result from:
²Contaminated lining in one caliper
²Seized caliper piston
²Binding caliper
²Loose caliper
²Rusty caliper slide surfaces
²Improper brake pads
²Damaged rotor
A worn, damaged wheel bearing or suspension
component are further causes of pull. A damaged
front tire (bruised, ply separation) can also cause
pull.
A common and frequently misdiagnosed pull condi-
tion is where direction of pull changes after a few
stops. The cause is a combination of brake drag fol-
lowed by fade at one of the brake units.
VABRAKES - BASE 5 - 3

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