Mercedes-Benz Sprinter / Dodge Sprinter. Manual — part 186
(5) Install differential cover (2) bolts (1) and tighen
to 45 N·m (33 ft. lbs.) (Fig. 52).
INSTALLATION
(1) Spread the differential housing (1).
CAUTION: Never spread over 0.3 mm (0.011 in). If
the housing is over-spread, it could be distorted or
damaged.
(2) Install differential case (2) into the housing (1)
with bearings, cups (3) and shims (Fig. 53).
(3) Loosely install differential bearing cap bolts.
(4) Remove spreader (2) and adapters (1) from
housing (Fig. 54).
(5) Tighten bearing cap bolts to 70 N·m (52 ft.
lbs.).
(6) Install axle shafts.
(7) Install differential cover and tighten bolts to 65
N·m (48 ft. lbs.).
(8) Fill differential housing with lubricant.
Fig. 52 DIFFERENTIAL COVER
1 - BOLTS
2 - COVER
Fig. 53 DIFFERENTIAL INSTALLATION
1 - HOUSING
2 - DIFFERENTIAL
3 - DIFFERENTIAL BEARINGS
Fig. 54 SPREADER
1 - ADAPTERS
2 - SPREADER
VA
REAR AXLE
3 - 37
BEARINGS - DIFFERENTIAL
CASE
REMOVAL
(1) Remove
differential
bearings
with
Puller
C-293-PA (1), Plug C-293-3 (2) and four Adapters
C-293-37 (3) (Fig. 55).
INSTALLATION
(1) Set differential on Plug C-293-3.
(2) Install
differential
(2)
bearings
(3)
with
Installer 9523 (4) and Handle C-4171 (1) (Fig. 56).
(3) Install differential case in axle.
Fig. 55 CASE BEARING PULLER
1 - PULLER
2 - PLUG
3- ADAPTERS
Fig. 56 DIFFERENTIAL BEARINGS
1 - HANDLE
2 - DIFFERENTIAL
3 - BEARING
4 - INSTALLER
3 - 38
REAR AXLE
VA
SEAL - PINION
REMOVAL
(1) Remove wheels.
(2) Push back brake pads and release hand brake.
NOTE: If it is not possible to spin rear axle shafts
manually, detach rear brake cables.
(3) Drain rear axle oil.
NOTE: On dual rear wheel axle remove axle shafts.
(4) Remove propeller shaft.
(5) Spin pinion flange by hand and check axial
play of bearing.
CAUTION: There must not be any thrust bearing
play. If play excess or there are particles (shavings)
in the drained oil, replace gear assembly.
(6) Measure and record torque to rotate the pinion.
(7) Mark pinion position to pinion flange (1) (Fig.
57).
(8) Unlock collared nut.
(9) Hold pinion flange (1) with Flange Wrench
C-3281 and remove nut.
(10) Remove pinion flange (1) from pinion shaft
with Flange Puller 8992 (2) (Fig. 58).
(11) Check sealing surfaces of joint flange for score
marks and replace joint flange if necessary.
(12) Remove pinion seal/seals (1) (Fig. 59).
Fig. 57 COLLARED NUT
1 - PINION FLANGE
2 - COLLARED NUT
Fig. 58 FLANGE PULLER
1 - FLANGE PULLER
2 - PINION FLANGE
Fig. 59 PINION SEALS
1 - SEALS
2 - AXLE
VA
REAR AXLE
3 - 39
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: Do not coat partially rubberized seals
with sealant.
(3) Drive new pinion seal/seals into rear axle
housing as far as the stop using Installer 9276 (2)
(Fig. 60).
(4) Fit coupling flange on drive pinion shaft.
NOTE: The groove in the drive pinion and the
groove in the joint flange must be in alignment.
(5) Hold pinion flange with Flange Wrench C-3281.
(6) Tighten collar nut to 100 N·m. (74 ft. lbs.).
(7) Using a dial indicator check free play at pinion
flange.
NOTE: Should bearing not be free of play, tighten in
increases of 10 N·m. (88 in. lbs.) to maximun of 130
N·m. (95 ft. lbs.). If bearing is not free from play at
130 N·m. (95 ft. lbs.) collapsible spacer must be
replaced.
(8) Identify the position of the pinion to the nut
twevle points and mark pinion and nut.
(9) Turn nut pinion nut 30° (one twelve point).
Them rotate pinion thirty times.
(10) Measure torque to rotate. The torque to rotate
must be 0.1-0.2 N·m (0.9-1.7 in. lbs.) higher then
recorded torque.
NOTE: If value is below or above collapsible spacer
must be replaced.
(11) Cut the collar of the collared nut (Fig. 61).
(12) Bend collar nut (1) so it touches the wall of
the slot in the pinion shaft (Fig. 62).
Fig. 60 PINION SEAL INSTALLER
1 - AXLE
2 - INSTALLER
Fig. 61 COLLARED NUT
Fig. 62 BEND COLLAR OF NUT
1 - COLLARED NUT
2 - DRIFT
3 - 40
REAR AXLE
VA
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