Sprinter 2005-2007

Axle Unit

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Removal & Installation



  1. Raise and safely support the vehicle.
  2.  
  3. Position a suitable lifting device under the axle and secure axle to device.
  4.  
  5. Remove the rear wheels.
  6.  
  7. Unplug wear indicator cable.
  8.  
  9. Detach cable connector for brake pad wear indicator.
  10.  
  11. 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.

  12.  
  13. Remove the cable ties from the park brake cables. Release the connection cable of brake pad wear indicator and ABS sensor cable up to the relay unit of the parking brake.
  14.  
  15. Remove the brake cables.
  16.  
  17. Remove the parking brake cable at relay unit.
  18.  
  19. Remove bracket for brake cables at rear axle tube.
  20.  
  21. Remove the stabilizer bar from axle brackets.
  22.  
  23. Remove the shock absorber mounting bolts from the rear axle.
  24.  
  25. Remove the ALB lever from the rear axle bracket.
  26.  
  27. Pull the vent line of the rear axle out of the frame.
  28.  
  29. Remove the driveshaft.
  30.  
  31. Remove the brake calipers
  32.  
  33. Remove the U-brackets and plates
  34.  
  35. Remove the axle from the vehicle.

    Click image to see an enlarged view

    Fig. Remove the lower shock mounting bolts (2) and U-Bolts (1) to remove the rear axle assembly.

  36.  

To install:

  1. Raise the rear axle into position.
  2.  
  3. Using new nuts, install the plates and U-brackets and tighten the nuts to 125 ft. lbs. (170 Nm).
  4.  
  5. Install the driveshaft.
    NOTE
    When installing the driveshaft, the joint arrows must be flush and must point towards the frame floor. Tighten the driveshaft in this position.

  6.  
  7. Install the ALB lever to axle bracket using a new nut and tighten to 25 ft. lbs. (34 Nm).
  8.  
  9. Install the shock absorber-to-rear axle mounting bolts.
  10.  
  11. Install the stabilizer bar-to-rear axle mounting bolts.
  12.  
  13. Install the brake calipers with adapters and lines.
  14.  
  15. Install the brake hoses and hold-down clips.
  16.  
  17. Install and adjust the parking brake cables.
  18.  
  19. Install the connection cable of brake pad wear indicator and ABS sensor cable up to the relay unit of the parking brake.
  20.  
  21. Install new cable ties to the park brake cables.
  22.  
  23. Install the ABS sensor and clamp bushing to mounting bore.
  24.  
  25. Attach the connector cable for brake pad wear indicator.
  26.  
  27. Plug in the cable of brake pad wear indicator.
  28.  
  29. Install the rear wheels.
  30.  
  31. Fill the rear axle with fluid to the correct level.
  32.  
  33. Remove the jack from underneath the axle.
  34.  
  35. Lower the vehicle.
  36.  

 
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