Mercedes-Benz Sprinter / Dodge Sprinter. Manual — part 174
(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
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FRONT
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(5) Remove the spring clamp plate and rubber
block.
(6) Remove the shear bushings from the front and
rear bolts.
INSTALLATION
(1) 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.
(2) Fit one spring clamp plate together with the
lower spring rubber block.
(3) Install the bolt with the shear bushing on the
rear mounting, Do not tighten yet.
(4) Install the four retaining bolts for the spring
clamp plate. Tighten to 65 N·m (48 ft.lbs.).
(5) Align the holes for the front clamp plate joint
using a suitable drift (shear bushing not installed).
(6) Remove the alignment drift.
(7) Insert the shear bushing and retaining bolt
into the hole and tighten to 130 N·m (96 ft.lbs.).
(8) Remove the jack and lower the vehicle.
SPRING STOP PLATES
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the tire and wheel assembly.
(3) Remove the lower end of the stabilizer link
from the stop plate.
(4) Remove the three bolts retaining the spring
stop plate from the lower control arm.
INSTALLATION
(1) Install the spring stop plate to the lower con-
trol arm. Tighten the bolts to 60 N·m (44 ft. lbs.).
(2) Install the stabilizer link to the spring stop
plate.
(3) Install the tire and wheel assembly.
(4) Lower the vehicle.
STABILIZER BAR
DESCRIPTION
The bar extends across the front underside of the
chassis and connects to the frame crossmember. The
ends of the bar mount to the lower suspension arm.
All mounting points of the stabilizer bar are isolated
by bushings (Fig. 10).
OPERATION
The stabilizer bar is used to minimize vehicle front
sway during turns. The bar helps to maintain a flat
attitude to the road surface.
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the stabilizer bar clamp bolts at the
front axle (Fig. 11).
(3) Press the rubber mount outwards out of the
brackets (Fig. 11).
(4) Remove the stabilizer links from the stabilizer
bar (Fig. 11).
INSTALLATION
(1) Install the stabilizer links to the stabilizer bar
(Fig. 11).
(2) Install the stabilizer to the front axle (Fig. 11).
Fig. 10 STABILIZER BAR
Fig. 11 STABILIZER BAR
1 - RUBBER MOUNT
2 - STABILIZER LINK
3 - RUBBER MOUNT
4 - NUT
5 - RUBBER MOUNT
6 - CLAMP BRACKET
7 - BOLT
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FRONT
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(3) Install the stabilizer bar clamp and bolts (Fig.
11). Tighten the bolts to 30 N·m (22 ft. lbs.).
(4) Lower the vehicle.
STABILIZER LINK
REMOVAL
(1) Raise and support the vehicle.
(2) Insert a pry bar between the stabilizer link and
something solid to pry on.
(3) Pry the stabilizer link off the stabilizer bar and
the spring stop plate.
INSTALLATION
(1) Install a mild detergent soap the to rubber
bushings on the stabilizer link.
(2) Install the stabilizer links onto the stabilizer
bar and spring stop plate by pushing on the link.
(3) Lower the vehicle.
STRUT
REMOVAL
(1) On the drivers side remove the floor covering
off to the side.
(2) On the passengers side take off the cover for
the tools.
(3) Remove the cover for the upper strut mounting
(Fig. 12).
(4) Remove the nut on the upper strut mounting
(Fig. 12).
(5) Raise and support the vehicle.
(6) Remove the front wheels.
(7) Raise the lower control arm approximately 10
mm with a jack to remove the tension from the strut.
(8) Remove the strut from the steering knuckle
(Fig. 12).
INSTALLATION
NOTE: Hand tighten the strut upper mounting nut
until the vehicle is on the ground, otherwise the
bushings may become distorted.
(1) Install strut to the steering knuckle (Fig. 12).
Tighten to 185 N·m (136 ft. lbs.).
(2) Raise the lower control to install the upper
part of the strut into the footwell. Tighten to 100
N·m (74 ft. lbs.).
(3) Install wheels (Refer to 22 - TIRES/WHEELS/
WHEELS - INSTALLATION).
(4) Lower the vehicle.
(5) Install the nut covers (Fig. 12).
(6) Refit the floor covering and the tool cover.
Fig. 12 STRUT
1 - COVER
2 - NUT
3 - RUBBER MOUNT
4 - STRUT
5 - STRUT BOLT
6 - LOCKING BOLT
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FRONT
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REAR
TABLE OF CONTENTS
page
page
REAR
. . . . . . . . . . . . . . . . . . . . . . . . 11
DIAGNOSIS AND TESTING - SPRING AND
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SHOCK
. . . . . . . . . . . . . . . . . . . . . . . . . . . 13
. . . . . . . . . . . . . . . . . . . . . . . 13
SPRING
. . . . . . . . . . . . . . . . . . . . . . . . 14
. . . . . . . . . . . . . . . . . . . . . . . . . 14
. . . . . . . . . . . . . . . . . . . 14
. . . . . . . . . . . . . . . . . . . 14
. . . . . . . . . . . . . . . 14
. . . . . . . . . . . . . . . 15
SPRING SHACKLE
. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
. . . . . . . . . . . . . . . . . . . . . . . 15
STABILIZER BAR
. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
. . . . . . . . . . . . . . . . . . . . . . . 15
STABILIZER LINK
. . . . . . . . . . . . . . . . . . . . . . . . . . . 16
. . . . . . . . . . . . . . . . . . . . . . . 16
REAR
DESCRIPTION
The rear suspension is comprised of:
• Shock Absorbers
• Jounce Bumpers
• Stabilizer Bar
• Leaf Springs
• Drive Axle
CAUTION: A vehicle should always be loaded so
the vehicle weight center-line is located immedi-
ately forward of the rear axle. Correct vehicle load-
ing provides proper front tire-to-road contact. This
results in maximum vehicle handling stability and
safety. Incorrect vehicle weight distribution can
cause excessive tire tread wear, spring fatigue or
failure, and erratic steering.
CAUTION: Suspension components with rubber/ure-
thane bushings (except stabilizer bar) should be
tightened with the vehicle at normal ride height. It is
important to have the springs supporting the weight
of the vehicle when the fasteners are torqued. If
springs are not at their normal ride position, vehicle
ride comfort could be affected and premature bush-
ing wear may occur.
DIAGNOSIS AND TESTING - SPRING AND
SHOCK
A knocking or rattling noise from a shock absorber
may be caused by movement between mounting
bushings and metal brackets or attaching compo-
nents. These noises can usually be stopped by tight-
ening the attaching nuts. If the noise persists,
inspect for damaged and worn bushings, and attach-
ing components. Repair as necessary if any of these
conditions exist.
A squeaking noise from the shock absorber may be
caused by the hydraulic valving and may be intermit-
tent. This condition is not repairable and the shock
absorber must be replaced.
The shock absorbers are not refillable or adjust-
able. If a malfunction occurs, the shock absorber
must be replaced. To test a shock absorber, hold it in
an upright position and force the piston in and out of
the cylinder four or five times. The action throughout
each stroke should be smooth and even.
The spring eye and shock absorber bushings do not
require any type of lubrication. Do not attempt to
stop spring bushing noise by lubricating them.
Grease and mineral oil-base lubricants will deterio-
rate the bushing rubber.
If the vehicle is used for severe, off-road operation,
the springs should be examined periodically. Check
for broken and shifted leafs, loose and missing clips,
and broken center bolts. Refer to Spring and Shock
Absorber Diagnosis chart for additional information.
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REAR
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