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According to the '06 owner's manual, any tranny fluid meeting MB spec. 236.12 is what should be used.

I broke off the red tab and then pushed out the remaining red plastic bit (catch it to use again) with a small screwdriver. After that, just pull off the black plastic cap with the internal O-ring. When you replace the black plastic cap, make sure the cap is clean and the O-ring is in place...

Re the exhaust brake, I estimate that my '02 already has an exhaust brake from the factory that soaks up about 67 hp max. In my opinion, that's pretty good for an engine that puts out 150-some hp on the power side and displaces 2.7 liters.

Look here: http://www.expeditersonline.com/cgi-bin/dcforum/dcboard_v2.cgi?az=show_thread&om=1788&forum=DCForumID16&omm=0

From the '03 servica manual: "DESCRIPTION The glow plug relay supplies battery voltage to the glow plug through a timed cycle that is related to coolant temperature. The glow plug relay is located under the battery. The purpose of a glow plug system is to improve combustion for low emissions...

RE: SPECS FOUND it's a long list folks Sprinter brake life has been reported by many and is all over the map. I just replaced my first front set on my '02 140" 2500SHC at 107k miles and the rears look like they'll last through the life of this new set. I learned during this replacement that...

RE: SPECS FOUND it's a long list folks Recently, while ordering parts & supplies for my '02, I talked w/Steve Schrock of Europarts (858-451-0020) and he said he was getting a lot of orders (dunno how many) from owners of high mileage '02s & '03s for cylinder heads. He said due to hairline...

What mpg did you actually get?

Looks like HT530 is the engine designation.

The addendum (yellow card) to the '06 owner's manual recommends tranny fluid every 60k miles and rear axle fluid every 4th maintenance service. Maintenance service (w/o ASSYST) is defined on p305 as every 30k miles. So, rear axle fluid every 120k miles w/o ASSYST.

Looks like some '07s are available here: http://www.truckpaper.com/listings/detail.aspx?OHID=1387292&guid=F7CD3A9F36BA4923B34B5E3A1778C41E

A different engine, but, according to the owner's manual, the Sprinter's engine oil consumption can be as high as 0.5% of the fuel consumed. Assuming a 10 mpg fuel consumption rate for the Cummins, that would mean 100 gal fuel for 1000 miles. At 0.5% of fuel consumed, that's max oil...

From the '03 service manual: WASHER FLUID LEVEL SWITCH DESCRIPTION The optional washer fluid level switch is a single pole, single throw switch that is integral to a unique version of the washer pump/motor unit, located rearward facing side of the washer reservoir, which is located in a...

The filler cap on my '02 is rusty - has been for a long time. Haven't had a problem with the harmonic balancer yet (98k miles).

The reason I asked about the flexplate is because the crankshaft position sensor works off the teeth on the flywheel and that controls injection timing. Don't know if it's possible to get the flexplate installed a little wrong (or maybe the crankshaft position sensor was damaged/bent when the...

Concerning your new flexplate and torque converter - did your original flexplate shatter/break?

Good post! Just one thing; on p307 of the '06 owner's manual: "Only use engine oil approved by DaimlerChrysler Corporation if following the ASSYST system guidelines." Doesn't say anything there about only MB spec 229.5 oil. And, on pp298-9 of this same document are oils listed meeting MB...

"The initial fill at for Sprinters is Mobile 1 0W 40, and even the Mopar oil that the dealers use for Sprinter oil changes is the same Mobile 1 0W 40, even if the oil is Mopar branded with the Mopar part number." If you're referring to the Mopar oil PN 04798231AD 15w40 MB spec 228.3 listed on...

Heard that some refineries in Texas were under exemption (don't know why), and are still being allowed to produce the <500 ppm LSD.

A couple other possibilities. If the EGR valve is dirty it could result in not quite enough oxygen in the charge to burn all the fuel. I take mine ('02) off and clean it every 30k miles. If the tranny torque converter doesn't lock, that could negatively affect mileage. If you're going down...