Sprinter 2005-2007

Pinion Seal

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Removal & Installation



  1. Raise and safely support the vehicle.
  2.  
  3. Remove the rear wheel.
  4.  
  5. Drain the rear differential fluid.
  6.  
  7. Remove the driveshaft. For additional information, refer to the following section, "Rear Driveshaft, Removal & Installation.-
  8.  
  9. Spin pinion flange by hand and check axial play of bearing.
    NOTE
    There must not be any thrust bearing play. If there excess play or there are particles (shavings) in the drained oil, the rear gear assembly must be replaced.

  10.  
  11. Measure and record the torque required to rotate the pinion.
  12.  
  13. Matchmark the pinion in position to pinion flange
  14.  
  15. Unlock the collared nut.
  16.  
  17. Using Special Tool C-3281 Flange Wrench, hold the pinion flange and remove nut.
  18.  
  19. Remove the pinion flange from pinion shaft using Special Tool 8992 Flange Puller.

    Click image to see an enlarged view

    Fig. Remove the pinion flange (2) from the shaft using Special Tool 8992 (1).

  20.  
  21. Check sealing surfaces of joint flange for score marks and replace joint flange if necessary.
  22.  
  23. Remove the pinion seals.
  24.  

To install:

  1. Pack the space between the dust lip and sealing lip on the seal ring with multi-purpose grease.
    NOTE
    On seals without rubberized external surface, coat outer circumference with sealant.


    WARNING
    Do not coat partially rubberized seals with sealant.

  2.  
  3. Drive new pinion seals into the rear axle housing until they stop using Special Tool 9276 Installer.

    Click image to see an enlarged view

    Fig. Drive new pinion seals into the axle housing (1) using Special Tool 9276 (2).

  4.  
  5. Fit the coupling flange on the drive pinion shaft.
    NOTE
    The groove in the drive pinion and the groove in the joint flange must be in alignment.

  6.  
  7. Hold the pinion flange with Special Tool C-3281 Flange Wrench C-3281 and tighten the pinion nut to 74 ft. lbs. (100 Nm).
  8.  
  9. Using a dial indicator check free play at the pinion flange.
    NOTE
    Should the bearing not be free of play, tighten in increases of 88 inch lbs. (10 Nm) to a maximum of 95 ft. lbs. (130 Nm). If the bearing is not free of play, the collapsible spacer must be replaced.

  10.  
  11. Identify the position of the pinion to the nut twelve points and mark pinion and nut. Turn the pinion nut 30° (one twelve point). Then rotate the pinion thirty times.
  12.  
  13. Measure the torque required to rotate. The torque to rotate must be 0.9-1.7 in. lbs. (0.1-0.2 Nm) higher then torque recorded during the removal procedure.
    NOTE
    If value is below or above collapsible spacer must be replaced.

  14.  
  15. Cut the collar of the collared nut.
  16.  
  17. Using a hammer and drift, bend the collar nut so it touches the wall of the slot in the pinion shaft.
  18.  
  19. Install the driveshaft.
  20.  
  21. Refill the rear differential with fluid to the correct level.
  22.  
  23. Install the wheel.
  24.  
  25. Operate brake pedal several times until brake pads contact brake discs (brake pressure built up).
  26.  
  27. Attach rear brake cables if removed and adjust parking brake.
  28.  

 
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