I have a 616 sprinter on a 2003. Diff compatibly

[ffc1971chris]

My question is can I remove the 5.75 diff and replace with a 4.85 are the 416 diffs compatible with a 616.
I'm aware that the ratio is gear to the the laiden weight of the vehicle but as my van is a motorhome I can reduce the weight to help with the new ratio.

 

[ffc1971chris]

Just ad some detail. My rear axle has twin wheels either side of the diff and has air brakes on the rear. So compatability is my main concern. The 416 has a 4.85 diff which would bring the rpm down to a better level when traveling at 60 mph on the motorway. At the moment at 60 the rpm is up around 3200 rpm.

 

[LostKiwi]

I'd imagine you can just swap over the crown wheel and pinion.

 

[clarkmichigan55b]

Enclose link to Mercedes van parts list. Click on yours and find rear axle section hope this helps.
Adrian.

http://www.catcar.info/mercedes/?la...zb3J0bWVudCBjbGFzcyIsIjIwIjoiVmFuLUV1cm9wZSJ9

 

[ffc1971chris]

Thanks ClarkMichigan. That was very helpful looks like there's only 2 options for me the 5.75 I have already or a 5.12. so hopefully I can source the right crown and pinion with the relevent shines and gaskets to make the modifications.
Thanks again Chris.

 

[clarkmichigan55b]

To save time the best thing to do is to go to your local Mercedes commercial dealer with your chassis number to check what is available and price.
Adrian.

 

[ffc1971chris]

Thanks for the advice I now know what I need to make the up grades. The diff or crown and pinion is 41:8 = 5:125 ratio.
Part number A9053500139.
This is a straight swap but my next problem is finding one. There are some availability in eastern Europe but the language barrier is impossible to breach. Anyone out there know of any supplier's that may help?

 

[ffc1971chris]

Main dealer can possibly help the part alone could be big money so hopefully I can find a cheaper supplier's possibly after market in Germany perhaps.

 

[clarkmichigan55b]

You could try HL Smith Transmission Ltd that rebuilds commercial vehicle transmissions. I see them in the trade magazines but i never had to use them so i cannot comment on their services.
https://www.hlsmith.co.uk/services/

 

[ffc1971chris]

Cheers I've given them a call I will let you know there response.cheers

 

[ffc1971chris]

HL Smith. Promised to reply to my request but never got back to me. I rang back but they fobbed me of.

 

[stumo]

I think the 61x is a much bigger diff than the 41x sprinter. Its more of a truck axle.

You can swap crownwheel and pinion between 41x and 31x Sprinters. But I think not 61x.

You will also need to change the SCN coding in your intrument cluster to the new ratio.

 

[ffc1971chris]

I was under the impression that the speed sensor came of the abs sensor. Which reads actual wheel rotation.

 

[stumo]

Yes the cluster gets the wheelspeeds from CAN from the ABS controller (if fitted). But it also contains the diff ratio in its coding. I beleive its got something to do with the ESP and traction control systems.

If you change the diff ratio without changing it in the IC coding it will go into limp mode

 

[ffc1971chris]

Ok thanks I will look into that. Not sure if my 2003 has esp. but I do appreciate your advice. Cheers Chris.

 

[ffc1971chris]

OK finally I have sorted the problem. After lots of digging I now know that the 616 sprinter only has 2 diff options. A 5:75 & 5:12 ratio. As I mentioned before my diff was a 5:75. This made my van incredibly fast but as a result it had high rpm on the motorway. At 60mph it was around 3500 rpm. So I sourced a new 5:12 crown wheel and pinion (wasn't cheap) from Italy then found a guy who rebuilds all the NHS ambulances axles. Which most are Mercedes to retro fit my new crown wheel and pinion. The whole job set me back £1300 but it was worth every penny. Its made such a difference. It now cruises along the motorway at 60mph with the rpm under 3000rpm. I am one happy camper.
AS a side note the crown wheel and pinion I purchased was delivered with a tiny bit of damage and I ended up in a dispute with the supplier. My fitter addressed the damage using a grinding stone cleaning up the small marks on the pinion from transit and every thing went together perfect. However the supplier refused to do anything about the damage but then strangely sent me a replacement anyway. I explained that I wanted the replacement but when they didn't offer to help I went ahead and had the first one fitted. I have since refused to return the second one telling them to arrange to collect. As a result they have said keep it and I now have a spare new crown wheel and pinion. Ironically the second one has very similar marks on it from transit.
Anyway anyone looking to do the modification to there 616 I have the hardware.
The crown wheel and pinion is £1400 from the main dealer so if you want to save a small fortune let me know.

 

[Tony hill]

Hi do you still have the 5.12 diff ? I’ve just bought an old 04 616 and it’s low geared also !

 

[ffc1971chris]

Hi do you still have the 5.12 diff ? I’ve just bought an old 04 616 and it’s low geared also !

Yes I do. I have both ratios up for sale.

 

[ffc1971chris]

5:12 is new I had 2 delivered

 

[ffc1971chris]

It makes a lot of difference when your on the motorway