Replacing the rear cuff (Mercedes-Benz Sprinter 903)

To remove the rear flange of the gearbox from the secondary (driven) shaft, you will need a two-legged puller and a suitable mandrel for pressing in the seal. The rear cuff must be replaced in the following sequence:

• put the car on supports;
• disconnect the cardan shaft and unscrew the intermediate support as described in section. "Removal and installation the gearbox";

• holding the gearbox drive flange, loosen fastening 1 (figure 193) a few turns without turning it completely;
• pull off the flange using a puller. Place the puller's paws behind the opposite flange projections, and rest the central rod against the loosened bolt - if it were removed, the shaft thread could be damaged. Remove the puller, unscrew the bolt, take out the washer, remove the flange;
• remove the cuff from the hole. In order not to damage the surrounding parts, you can screw two screws into the cuff and remove it using pliers and a screwdriver;
• apply grease between the working edges of the new seal and press it in using a mandrel of suitable diameter. Remove excess grease;

• install the flange on the shaft splines, the washer and tighten the bolt (figure 194);
• holding the flange from turning, tighten the bolt to a torque of 110 Nm;
• insert the cardan shaft and tighten the fastening bolts (60–65 Nm);
• install the intermediate support of the propeller shaft (85–90 N·m);
• install a safety bracket under the cardan shaft and tighten the bolts (85–90 N·m).