Mercedes-Benz Sprinter / Dodge Sprinter. Manual — part 187
(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) and tighten to 100
N·m (74 ft. lbs.).
(16) Install wheels at rear axle.
(17) Operate brake pedal several times until brake
pads contact brake discs (brake pressure built up).
(18) Attach rear brake cables if removed and
adjust parking brake.
GEAR - PINION / RING
REMOVAL
NOTE: The ring and pinion gears are serviced in a
matched set. Never replace one gear without replac-
ing the other gear.
(1) Remove differential from housing.
(2) Place differential case in a vise with soft metal
jaw.
(3) Remove ring gear bolts from the differential
case.
(4) Drive ring gear off the differential case with a
dead-blow hammer (Fig. 64).
(5) Unlock collared nut.
(6) Hold pinion flange with Flange Wrench C-3281
and remove nut.
(7) Remove pinion flange from pinion shaft with
Puller 8892 and Wrench C-3281 (Fig. 65).
(8) Remove pinion gear from housing with a dead-
blow hammer.
(9) Remove pinion shaft seal with a seal pick.
(10) Remove front pinion bearing.
(11) Remove
front
pinion
bearing
cup
with
Remover D-103 and Handle C-4171.
(12) Remove rear pinion bearing cup with Remover
9084 and Handle C-4171.
(13) Remove pinion depth shim from rear pinion
bearing cup bore.
(14) Remove collapsible spacer (Fig. 66).
Fig. 63 FILL PLUG
1 - FILL PLUG
2 - DRAIN PLUG
Fig. 64 RING GEAR
1 - CASE
2 - RING GEAR
3 - DEAD-BLOW HAMMER
Fig. 65 FLANGE PULLER
1 - FLANGE PULLER
2 - PINION FLANGE
VA
REAR AXLE
3 - 41
(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 equivalent lubricant
to outside surface of bearing cups.
(2) Install pinion depth shim in rear pinion bear-
ing cup bore.
(3) Install rear pinion bearing cup with Installer
C-4310 and Driver Handle C-4171.
(4) Install front pinion bearing cup with Installer
8617 and Handle C-4171.
(5) Install rear bearing on pinion with Installer
MB-998805 and a press (Fig. 69).
Fig. 66 COLLAPSIBLE SPACER
1 - COLLAPSIBLE SPACER
2 - SPACER
Fig. 67 SPACER
1 - SPACER
2 - PINION SHAFT
Fig. 68 Rear Bearing Removal
1 - PULLER
2 - VISE
3 - ADAPTERS
4 - DRIVE PINION GEAR SHAFT
3 - 42
REAR AXLE
VA
(6) Install pinion spacer on pinion shaft (Fig.
70).
(7) Install new collapsible preload spacer on pin-
ion shaft (Fig. 71) and install pinion gear into the
housing.
(8) Install front pinion bearing into housing with
Installer 9548.
(9) Apply a light coating of gear lubricant on the
lip of pinion seal and install seal with Installer 9276
(Fig. 72).
(10) Hold
pinion
flange
with
Flange
Wrench
C-3281.
(11) Screw on the new collared nut.
(12) Tighten collar nut carefully to a torque to
rotate of 2.5-3 N·m (22-27 in. lbs.).
(13) Cut the collar of the tightened collared nut
(Fig. 73).
Fig. 69 REAR BEARING INSTALLATION
1 - PRESS
2 - INSTALLER
3 - DRIVE PINION GEAR
4 - REAR PINION BEARING
Fig. 70 SPACER
1 - SPACER
2 - PINION SHAFT
Fig. 71 COLLAPSIBLE SPACER
1 - COLLAPSIBLE SPACER
2 - SPACER
Fig. 72 PINION SEAL INSTALLER
1 - AXLE
2 - INSTALLER
VA
REAR AXLE
3 - 43
(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.
(16) Invert differential case in the vise and install
new ring gear bolts and alternately tighten to 180
N.m (133 ft. lbs.) (Fig. 75)
CAUTION: Do not reuse ring gear bolts, the bolts
can fracture causing extensive damage. Failure to
heed caution may result in damage.
(17) Install differential in axle housing and verify
gear mesh and contact pattern.
Fig. 73 COLLARED NUT
Fig. 74 BEND COLLAR OF NUT
1 - COLLARED NUT
2 - DRIFT
Fig. 75 RING GEAR
1 - TORQUE WRENCH
2 - RING GEAR BOLT
3 - RING GEAR
4 - CASE
3 - 44
REAR AXLE
VA
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