Mercedes-Benz Dodge Freightliner Sprinter W901 W902 W903 W904 W905 W906 T1N 1995-2018 Workshop Repair Service Manual PDF - MMB901W906T1.zip
This is a full-service repair manual, complete with electrical wiring diagrams, covering Mercedes Benz / Dodge / Freightliner Sprinter W901/W902/W903/W904/W905/W906 vans from 1995 through 2018. Inside you'll find every technical detail needed to service, troubleshoot, fix, and rebuild these vehicles the way a professional technician would.
The Mercedes Benz / Dodge / Freightliner Sprinter W901/W902/W903/W904/W905/W906 workshop service repair manual contains:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 21,999 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
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MAKE: Mercedes-Benz / Freightliner / Dodge
MODEL: W901/W902/W903/W904/W905/W906 Sprinter (a.k.a. Mercedes-Benz Transporter T1N, Sprinter, Sprinter, Sprinter 4x4)
YEAR: 1995-2018
MAIN SECTIONS
Dodge_Freightliner Sprinter (VA Chassis, 001. GEN) (1995-2006) Service Manual...2
VA Service Manual...2
GROUP TAB LOCATOR...2
in-INTRODUCTION...4
VEHICLE IDENTIFICATION NUMBER...4
DESCRIPTION...4
INTERNATIONAL SYMBOLS...5
DESCRIPTION...5
FASTENER IDENTIFICATION...5
DESCRIPTION...5
FASTENER USAGE...8
DESCRIPTION - FASTENER USAGE...8
THREADED HOLE REPAIR...8
DESCRIPTION - THREADED HOLE REPAIR...8
METRIC SYSTEM...8
DESCRIPTION...8
TORQUE REFERENCES...10
DESCRIPTION...10
0-LUBRICATION & MAINTENANCE...12
FLUID TYPES...12
DESCRIPTION...12
DESCRIPTION - FUEL REQUIREMENTS - DIESEL ENGINE...12
DESCRIPTION...12
DESCRIPTION - ENGINE COOLANT...12
ETHYLENE-GLYCOL MIXTURES...12
PROPYLENE-GLYCOL MIXTURES...13
DESCRIPTION - HOAT COOLANT...13
COOLANT PERFORMANCE...13
COOLANT SELECTION AND ADDITIVES...14
DESCRIPTION - AXLE...14
REAR AXLE...14
DESCRIPTION - BRAKE FLUID...14
BRAKE FLUID...14
DESCRIPTION - POWER STEERING FLUID...14
POWER STEERING FLUID...14
DESCRIPTION - ENGINE OIL - DIESEL ENGINES...14
SAE VISCOSITY GRADE...14
DESCRIPTION - AUTOMATIC TRANSMISSION FLUID - NAG1...15
FLUID ADDITIVES...15
OPERATION - AUTOMATIC TRANSMISSION FLUID...15
FLUID CAPACITIES...15
SPECIFICATIONS - FLUID CAPACITIES...15
FLUID FILL/CHECK LOCATIONS...15
INSPECTION - FLUID FILL/CHECK LOCATIONS...15
PARTS & LUBRICANT RECOMMENDATION...16
STANDARD PROCEDURE - PARTS & LUBRICANT RECOMMENDATIONS...16
HOISTING...16
STANDARD PROCEDURE - HOISTING...16
FLOOR JACK...16
HOIST...16
JUMP STARTING...17
STANDARD PROCEDURE - JUMP STARTING...17
TO JUMP START A DISABLED VEHICLE:...17
DISCONNECT CABLE CLAMPS AS FOLLOWS:...17
TOWING...17
STANDARD PROCEDURE - TOWING...17
If the Engine is Damaged...18
If the Transmission is Damaged...18
If the Front Axle is Damaged...18
If the Rear Axle is Damaged...18
SAFETY PRECAUTIONS...18
GROUND CLEARANCE...18
RAMP ANGLE...18
TOWING WHEN KEYS ARE NOT AVAILABLE...18
MAINTENANCE SCHEDULES...18
DESCRIPTION...18
MAINTENANCE - WITHOUT ASSYST MAINTENANCE COMPUTER...18
MAINTENANCE - WITH ASSYST MAINTENANCE COMPUTER...19
REGULAR CHECK-UPS...19
SPECIAL MAINTENANCE REQUIREMENTS...19
ENGINE OIL CHANGE AND FILTER REPLACEMENT...19
SCOPE OF WORK FOR MAINTENANCE SERVICE...19
ADDITIONAL MAINTENANCE WORK...20
ADDITIONAL MAINTENANCE WORK AFTER YEARS...20
INTERNATIONAL SYMBOLS...20
DESCRIPTION...20
2-SUSPENSION...22
FRONT...22
FRONT...23
SPECIFICATIONS - TORQUE CHART...23
SPECIAL TOOLS...23
FRONT SUSPENSION...23
BUSHINGS...24
REMOVAL...24
INSTALLATION...24
HUB / BEARING...25
DIAGNOSIS AND TESTING -...25
REMOVAL...25
INSTALLATION...26
KNUCKLE...26
REMOVAL...26
INSTALLATION...26
LOWER BALL JOINT...27
REMOVAL...27
INSTALLATION...27
LOWER CONTROL ARM...27
REMOVAL...27
INSTALLATION...27
SPRING...28
REMOVAL...28
INSTALLATION...29
SPRING CLAMP PLATES...29
REMOVAL...29
INSTALLATION...29
SPRING STOP PLATES...30
REMOVAL...30
INSTALLATION...30
STABILIZER BAR...30
DESCRIPTION...30
OPERATION...30
REMOVAL...30
INSTALLATION...30
STABILIZER LINK...30
REMOVAL...30
INSTALLATION...30
STRUT...31
REMOVAL...31
INSTALLATION...31
REAR...32
REAR...32
DESCRIPTION...32
DIAGNOSIS AND TESTING - SPRING AND SHOCK...32
SPECIFICATIONS - TORQUE CHART...33
SHOCK...34
DIAGNOSIS AND TESTING - SHOCK...34
REMOVAL...34
INSTALLATION...34
SPRING...35
DESCRIPTION...35
OPERATION...35
REMOVAL...35
REMOVAL - (SRW)...35
REMOVAL - (DRW)...35
INSTALLATION...35
INSTALLATION - (SRW)...35
INSTALLATION - (DRW)...36
SPRING SHACKLE...36
REMOVAL...36
INSTALLATION...36
STABILIZER BAR...36
REMOVAL...36
INSTALLATION...36
STABILIZER LINK...37
REMOVAL...37
INSTALLATION...37
WHEEL ALIGNMENT...38
WHEEL ALIGNMENT...38
DESCRIPTION...38
DIAGNOSIS AND TESTING - PRE-ALIGNMENT INSPECTION...38
STANDARD PROCEDURE - TOE ADJUSTMENT...40
SPECIFICATIONS...40
3-DIFFERENTIAL & DRIVELINE...42
PROPELLER SHAFT...42
PROPELLER SHAFT...42
DIAGNOSIS AND TESTING...42
PROPELLER SHAFT VIBRATION...42
PROPELLER SHAFT BALANCE...43
PROPELLER SHAFT RUNOUT...44
STANDARD PROCEDURE...44
PROPELLER SHAFT ANGLE...44
TWO/THREE-PIECE PROPELLER SHAFT...45
SPECIFICATIONS...46
SPECIAL TOOLS...46
PROPELLER SHAFT...47
REMOVAL...47
INSTALLATION...47
CENTER BEARING...49
REMOVAL...49
INSTALLATION...50
REAR AXLE...51
REAR AXLE...51
DESCRIPTION...51
OPERATION...51
DIAGNOSIS AND TESTING...51
GEAR NOISE...51
BEARING NOISE...51
LOW SPEED KNOCK...52
VIBRATION...52
DRIVELINE SNAP...52
STANDARD PROCEDURE - DRAIN AND FILL...52
REMOVAL...52
INSTALLATION...53
SPECIFICATIONS...54
SPECIAL TOOLS...55
AXLE SHAFTS...56
REMOVAL...56
INSTALLATION...56
AXLE BEARINGS/SEALS...58
REMOVAL...58
INSTALLATION...58
AXLE SHAFTS - DUAL REAR WHEELS...60
REMOVAL...60
INSTALLATION...60
AXLE HUB BEARINGS/SEALS...61
REMOVAL...61
INSTALLATION...61
PINION SEAL...63
REMOVAL...63
INSTALLATION...63
5-BRAKES...66
BRAKES - BASE...66
BRAKES - BASE...67
DIAGNOSIS AND TESTING - BASE BRAKE SYSTEM...67
PRELIMINARY BRAKE CHECK...67
ROAD TESTING...68
BRAKE NOISES...69
STANDARD PROCEDURE...69
STANDARD PROCEDURE - MANUAL BLEEDING...69
STANDARD PROCEDURE - PRESSURE BLEEDING...70
HYDRAULIC/MECHANICAL...70
SPECIFICATIONS...70
SPECIFICATIONS - TORQUE CHART...70
BASE BRAKE...71
SPECIAL TOOLS...72
BRAKES...72
BRAKE LINES...73
STANDARD PROCEDURE...73
STANDARD PROCEDURE - ISO FLARING...73
STANDARD PROCEDURE - DOUBLE INVERTED FLARING...73
BRAKE PADS/SHOES...74
REMOVAL...74
REMOVAL - FRONT (SRW)...74
REMOVAL - FRONT (DRW)...74
REMOVAL - REAR (16 WHEELS) (SRW)...74
REMOVAL - REAR (15 WHEELS) (SRW)...74
REMOVAL - REAR (DRW)...75
INSTALLATION...75
INSTALLATION - FRONT (SRW)...75
INSTALLATION - FRONT (DRW)...76
INSTALLATION - REAR (16 WHEELS) (SRW)...76
INSTALLATION - REAR (16 WHEELS) (SRW)...76
INSTALLATION - REAR (DRW)...76
DISC BRAKE CALIPERS...76
REMOVAL...76
REMOVAL - FRONT (SRW)...76
REMOVAL - FRONT (DRW)...77
REMOVAL - REAR (SRW)...77
REMOVAL - REAR (DRW)...77
INSTALLATION...77
INSTALLATION - FRONT (SRW)...77
INSTALLATION - FRONT (DRW)...78
INSTALLATION - REAR (SRW)...78
INSTALLATION - REAR (DRW)...78
DISC BRAKE CALIPER ADAPTER...78
REMOVAL...78
REMOVAL - FRONT...78
REMOVAL - REAR...78
INSTALLATION...79
INSTALLATION - FRONT...79
INSTALLATION - REAR...79
FLUID...79
DIAGNOSIS AND TESTING - BRAKE FLUID CONTAMINATION...79
STANDARD PROCEDURE - BRAKE FLUID LEVEL...79
SPECIFICATIONS...79
BRAKE FLUID...79
FLUID RESERVOIR...80
REMOVAL...80
INSTALLATION...80
ALB LEVER...80
REMOVAL...80
INSTALLATION...80
ALB CONTROLLER...80
REMOVAL...80
INSTALLATION...80
ADJUSTMENTS...81
ADJUSTMENT...81
MASTER CYLINDER...81
DIAGNOSIS AND TESTING - MASTER CYLINDER/POWER BOOSTER...81
POWER BOOSTER VACUUM TEST...82
POWER BOOSTER CHECK VALVE TEST...82
STANDARD PROCEDURE - MASTER CYLINDER BLEEDING...82
REMOVAL...82
INSTALLATION...83
PEDAL...83
REMOVAL...83
INSTALLATION...84
POWER BRAKE BOOSTER...84