MERCEDES-BENZ ML350 1997 Complete Repair Manual

Wheel location, hub
Remove/install wheels,
rotate if necessary AP40.10-P-
4050GH
2
Detach hexagon collared
nut (65a) from front axle
shaft Replace hexagon nut with collar
*BA33.30-P-
1001-02B
3Remove front axle brake
caliper
Hang the floating / fixed caliper to one side with a
hook to relieve the strain on the brake hose.
Leave brake hose connected.

Model 163.136, model 163.113 up to VIN A289564,
X754619, model 163.154 up to VIN A289564, model
163.154 /157 only with US version, code 494a.AR42.10-P-
0070GH
Model 163.128 /172 /174 /175, model 163.113 as of
VIN A289565, X754620, model 163.154 as of VIN
A289565, model 163.154 /157 except US version,
code 494a.
AR42.10-P-
0070GI
4Detach track rod from
steering knuckle
Check rubber boot and ball joint for wear and
damage.AR46.40-P-
0200-02C
*BA46.40-P-
1001-01C
Thrust pieceFig. 16
PullerFig. 17
5
Press follower joint out of
upper transverse control
arm using puller
Check rubber boot and ball joint for wear and damageAR33.20-P-
0500-01GH
*BA33.20-P-
1001-01D
Thrust pieceFig. 45
SupportFig. 46
PressFig. 47
6
Press front axle shaft (65)
out of front axle shaft
flange Hang steering knuckle to one side using wire.AR33.30-P-
0620-04GH
Extraction and installation toolFig. 18
7Lever front axle shaft out
of front axle gear Do not damage shield.
8Remove front axle shaft
(65) Installation: Make sure that the opening in the
circlip (65c) faces downward before inserting into the
front axle gear.

9Install in the reverse order
NumberDesignationModel
163
BA33.20-P-1001-
01DSelf-locking nut, upper transverse control arm follower joint to
steering knuckleNm50

2001 Mercedes-Benz ML320
1998-2005 DRIVELINE/AXLES Front Axle - 163 Chassis
me
Saturday, October 02, 2010 3:38:22 PMPage 52 © 2006 Mitchell Repair Information Company, LLC.

Front axle shaft
Track rod
Fig. 89: Identifying Thrust Piece (140 589 00 63 00)

Fig. 90: Identifying Puller (202 589 02 33 00)

Fig. 91: Identifying Thrust Piece (129 589 10 63 00)
NumberDesignationModel 163
BA33.30-P-1001-02BNut, front axle shaft to front axle shaft flangeNm490
NumberDesignationModel 163
BA46.40-P-1001-01CSelf-locking nut, track rod to steering knuckleNm55

2001 Mercedes-Benz ML320
1998-2005 DRIVELINE/AXLES Front Axle - 163 Chassis
me
Saturday, October 02, 2010 3:38:22 PMPage 53 © 2006 Mitchell Repair Information Company, LLC.

Fig. 92: Identifying Support (163 589 01 43 00)
Fig. 93: Identifying Press (163 589 03 43 00)

Fig. 94: Identifying Extraction A nd Installation Tool (210 589 03 43 00)

DETACHING AND ATTACHING RUBBER BOOTS AT JOINT - AR33.30-P-0660-01GH
Front axle shaft
Commercially available tools
NumberDesignationModel 163
BF33.30-P-1001-02CFilling capacityInner joint rubber bootg155
Inner joint inner chamberg110
BF33.30-P-1002-02CFilling capacityOuter joint rubber bootg155
Outer joint inner chamberg65
NumberDesignation
WH58.30-Z-1011-02AClamping pliers

2001 Mercedes-Benz ML320
1998-2005 DRIVELINE/AXLES Front Axle - 163 Chassis
me
Saturday, October 02, 2010 3:38:22 PMPage 54 © 2006 Mitchell Repair Information Company, LLC.

Removal:
1.1 Remove hose clamps with tab (37n, 37 r and 37k, 37q) using side cutting pliers.
Shown on outer joint, hose clamp with tab, 1st version
Fig. 95: Identifying Ho se Clamps With Tab
- 1St Version
1.2 Open and remove large hose clamps with tens ioning bead (37n, 37k) using pliers (078). Remove
small hose clamps with tab (37r, 37q) using side cutting pliers.
2 Pull off rubber boot.
Shown on outer joint, large hose clam p with tensioning bead, 2nd version.
Fig. 96: Identifying Large Hose Clamps With Tensioning Bead
- 2nd Version

2001 Mercedes-Benz ML320
1998-2005 DRIVELINE/AXLES Front Axle - 163 Chassis
me
Saturday, October 02, 2010 3:38:22 PMPage 55 © 2006 Mitchell Repair Information Company, LLC.

Fig. 97: Identifying Front Axle Shaft Components
Installation
3 Scrape grease off inside of rubber boot and pack into joint; replace grease if necessary. Observe filling
quantity.
4 Push new rubber boot into correct position.
Replace hose clamps.
5.1 Press hose clamps with tab (37n, 37r and 37k, 37q) together using suitable commercially-available
pincers. Check that the hose clamps are properly seated.
The connection of the hose clamp on the inner joint must be at 180° to the connection of the hose
clamp on the outer joint so that no imbalance is produced.
Shown on outer joint, hose clamp with tab, 1st version
Fig. 98: Identifying Hose Clamps With Tab
- 1st Version
5.2 Mount large hose clamps with tensioning bead (37n, 37k) using pliers (078). Press small hose clamps
with tab (37r, 37q) together using suitable commercially-available pincers. Check that the hose clamps
are properly seated.

2001 Mercedes-Benz ML320
1998-2005 DRIVELINE/AXLES Front Axle - 163 Chassis
me
Saturday, October 02, 2010 3:38:22 PMPage 56 © 2006 Mitchell Repair Information Company, LLC.

Shown on outer joint, large hose clamp with tensioning bead, 2nd version.
Fig. 99: Identifying Large Hose Clamps With Tensioning Bead
- 2nd Version
DRIVING OUT AND PRESSING ON OUTER JOINT - AR33.30-P-0660-02GH
Driving out
1. Drive out outer joint (37b) using 32 mm open wrench.
Fig. 100: Identifying Driving Out Outer Joint

Pressing on
2. Install new locking ring (37p).
3. Press on outer joint (37b) making sure that the locking ring (37p) engages in the joint hub.

2001 Mercedes-Benz ML320
1998-2005 DRIVELINE/AXLES Front Axle - 163 Chassis
me
Saturday, October 02, 2010 3:38:22 PMPage 57 © 2006 Mitchell Repair Information Company, LLC.

Fig. 101: Identifying Oute r Joint And Locking Ring
REPLACE RUBBER BOOTS ON FRONT AXLE SHAFT - AR33.30-P-0660GH
MODEL 163.113 /128 /136 /154 /157 /172 /174 /175
Fig. 102: Identifying Fron t Axle Shaft Components

Removing
1Remove front axle shaft (37) AR33.30-P-
0620GH

Disassemble/assemble
2
Detach inner rubber boot (37l) or
outer rubber boot (37m) from ball
joint
AR33.30-P-
0660-01GH
Inner ball joint: ?
*BF33.30-P-
1001-02C

2001 Mercedes-Benz ML320
1998-2005 DRIVELINE/AXLES Front Axle - 163 Chassis
me
Saturday, October 02, 2010 3:38:22 PMPage 58 © 2006 Mitchell Repair Information Company, LLC.

Front axle shaft
MAINTENANCE
FRONT AXLE CARRIER - RETIGHTENING BOLTS - AP33.10-P-3373GH
MODEL 4JG163.### ## up to 221505, WDC163.### ## up to 734087
Outer joint: ?
*BF33.30-P-
1002-02C
3Drive out outer joint (37b) AR33.30-P-
0660-02GH
4
Pull inner rubber boot (37l) or outer
rubber boot (37m) off front axle
shaft (37)
Removal:
Left-hand front axle shaft:
The inner rubber boot (37l) can only be
removed when the outer joint (37b) is
driven out.
Right-hand front axle shaft:
The inner rubber boot (37l) cannot be
replaced as the shaft has a reinforcement in
the center.
If necessary, replace front axle shaft
Installation: To push on the rubber
boots, place suitable assembly sleeve on
the splined shaft profile of the rear axle
shaft.

5Replace circlips (37o, 37p)
6Assemble in the reverse order
Install
7Install front axle shaft (37) AR33.30-P-
0620GH
NumberDesignationModel 163
BF33.30-P-1001-02CFilling capacityInner joint rubber bootg155
Inner joint inner chamberg110
BF33.30-P-1002-02CFilling capacityOuter joint rubber bootg155
Outer joint inner chamberg65

2001 Mercedes-Benz ML320
1998-2005 DRIVELINE/AXLES Front Axle - 163 Chassis
me
Saturday, October 02, 2010 3:38:22 PMPage 59 © 2006 Mitchell Repair Information Company, LLC.

Fig. 103: Identifying Front Axle Carrier - Retightening Bolts
Front axle carrier
INSPECT FRONT AXLE JOINT FOR PLAY, INSPECT RUBBER BOOTS - AP33.20-P-3353GH
MODEL 163.113 /128 /136 /154 /157 /172 /174 /175
Tightening

Lethal injuries are
possible if vehicle slips off
of lifting platformAlign vehicle between lifting platform columns and
position the four hoisting plates beneath the lifting
platform mounting points specified by the vehicle
manufacturer.
AS00.00-Z-
0010-01A
1Place vehicle on lift
2Torque axle carrier bolts
(1) *BA33.10-P-
1001-01C
NumberDesignationModel 163 up to 31/08/00
BA33.10-P-1001-01CBolt, front axle carrier to frameNm200

2001 Mercedes-Benz ML320
1998-2005 DRIVELINE/AXLES Front Axle - 163 Chassis
me
Saturday, October 02, 2010 3:38:22 PMPage 60 © 2006 Mitchell Repair Information Company, LLC.

Fig. 104: Identifying Supporting Joint, Bottom Track Control Arm And Rubber Boots
Fig. 105: Identifying Supporting Joint, Transverse Control Arm And Dial Gage Holder

Remove

Risk of death. Death may result if
vehicle slips or topples from the
lifting platform.Align vehicle between columns of lifting
platform and position the four support plates
below support points specified by vehicle
manufacturer.
AS00.00-Z-
0010-01A
1Remove front wheels AP40.10-P-
4050GH
Inspect
2Check rubber boot (7f) on
supporting joint for leakage and
condition Visual inspection, if rubber boot is leaking
(e.g. grease flowing out): ?
Replace supporting jointAR33.20-P-
0440GH
3Check rubber boot (8f) on follower
joint for leakage and condition.
Visual inspection, if rubber boot is leaking
(e.g. grease flowing out): ?
Replace upper transverse control armAR33.20-P-
0500GH
4
Mount dial gage (022) with gage
stand (015) on the underside of the
transverse control arm (4) and pre-
tension The feeler must be set firmly up against the
face of the supporting joint dome cap (7) with
an indicating pretightening of 3mm.

5
Steering angle must not be altered while
measuring.
Determine the amount of play in the
supporting joint (7) through vertical pulling


2001 Mercedes-Benz ML320
1998-2005 DRIVELINE/AXLES Front Axle - 163 Chassis
me
Saturday, October 02, 2010 3:38:22 PMPage 61 © 2006 Mitchell Repair Information Company, LLC.