suspension MERCEDES-BENZ ML500 1997 Complete Owner's Guide

Fig. 15: Identifying Rear Shock Absorber Components
Remove/Install
Risk of injury with
trapped or crushed
fingers when working on
springs or spring-loaded
componentsUse only approved
tensioning devices;
additionally shield off
hazardous area if
necessary.
Inspect special tools for
damage and proper
operation (visual
inspection).
Wear protective gloves.AS00.00-Z-0001-01A
Notes on self-locking nuts
and boltsAll modelsAH00.00-N-0001-01A
1Remove spring strut from
rear axle AR32.25-P-1016GH
2Remove shock absorber
from spring strut AR32.25-P-0200-07GH
Spring
compressorFig. 2
Tensioning platesFig. 3
*BA32.25-P-1003-03D
3Shock absorber inspectionInstall new shock AR32.25-P-0121A

2001 Mercedes-Benz ML320
1998-2005 SUSPENSION Suspension - 163 Chassis
me
Saturday, October 02, 2010 3:37:35 PMPage 16 © 2006 Mitchell Repair Information Company, LLC.

Rear axle shock absorber
Fig. 16: Identifying Tensioning Device (203 589 01 31 00)

Fig. 17: Identifying Tensioning Plates (163 589 00 63 00)

CHECKING SHOCK ABSO RBER - AR32.25-P-0121A
MODEL 129
MODEL 140
MODEL 163.113 /128 /136 /154 /157 /172 /174 /175
absorber if necessary.
Disposing of shock
absorber OS32.25-P-0121-01GH
4Install in reverse sequence.
NumberDesignationModel Series 163
BA32.25-P-1003-03DSelf-locking nut, shock
absorber to rear springNM30

2001 Mercedes-Benz ML320
1998-2005 SUSPENSION Sus pension - 163 Chassis
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MODEL 168
MODEL 170
MODEL 202
MODEL 203
MODEL 208
MODEL 209.3/ 4
MODEL 210 except CODE (489) Airmatic (semi-active air suspension)
MODEL 211.0 /2 /6 except CODE (489) Airmatic (semi-active air suspension)
MODEL 414
MODEL 230 except CODE (487) Active Body Control (ABC)
MODEL 164, 251 except CODE (489) Airmatic (air suspension with level adjustment and adaptive
damping system ADS)
Shown on shock absorber in model 202
Fig. 18: Identifying Extension Dimension
- Shown On Shock Absorber In Model 202
Checking
1.1Check piston rod for
surface damage, bending
and for moving in the
guide bush without
jamming
Only if the old shock
absorber is to be installed
again.
Dispose of shock
absorber if necessary.

2001 Mercedes-Benz ML320
1998-2005 SUSPENSION Suspension - 163 Chassis
me
Saturday, October 02, 2010 3:37:36 PMPage 18 © 2006 Mitchell Repair Information Company, LLC.

By workshop: ?
Disposing of shock
absorberModel 129, 140, 170, 202,
208, 210OS32.25-P-0121-01A
Models 163, 164, 251OS32.25-P-0121-01GH
Model 168, 203, 209,
414.700OS32.25-P-0121-01GC
Model 211OS32.25-P-0121-01TX
Model 230
Disposal by scrap
dealer: ?
Notes on scrapping gas-
filled hydraulic
componentsOS00.00-P-1000-01A
2.1Check damper for
external oil leaks Only if the old shock
absorber is to be installed
again
A thin film of oil on the
shock absorber is
permissible.
Dispose of shock
absorber if necessary.
By workshop: ?
Disposing of shock
absorberModel 129, 140, 170, 202,
208, 210OS32.25-P-0121-01A
Models 163, 164, 251OS32.25-P-0121-01GH
Model 168, 203, 209,
414.700OS32.25-P-0121-01GC
Model 211OS32.25-P-0121-01TX
Model 230
Disposal by scrap
dealer: ?
Notes on scrapping gas-
filled hydraulic
componentsOS00.00-P-1000-01A
3.1Check shock absorber for
internal leakage Only if the old shock
absorber is to be installed
again.
This test is not possible
on models 140, 163, 164,
168, 203, 209, 251,
414.700.
The volume of oil in
the shock absorber is
determined by means of

2001 Mercedes-Benz ML320
1998-2005 SUSPENSION Suspension - 163 Chassis
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Test values for shock absorber
the projection length (a) of
the piston rod.
Push in piston rod as
far as it will go. Then hold
vertically so that piston
rod points down, and
measure projection length
(a) of piston rod.
Shock absorber in new
condition:
Shock absorber in used
condition:
Model 129, 170, 202, 208,
210, 211, 230*BE32.25-P-1002-02A
Model 129, 170, 202, 208,
210, 211, 230
If shock absorber exceeds
specified value, dispose of
it:
By workshop: ?*BE32.25-P-1001-02A
Disposing of shock
absorberModel 129, 170, 202, 208,
210OS32.25-P-0121-01A
Model 211OS32.25-P-0121-01TX
Model 230
Disposal by scrap
dealer: ?
Notes on scrapping gas-
filled hydraulic
componentsOS00.00-P-1000-01A
4.1Check rubber mount in
housing eye, replace if
necessary Only on shock
absorbers with rubber
mount in housing eye and
only if the shock absorber
is not replaced.
The rubber mounts
must be seated securely in
the body eye and must not
be cracked or damaged.
If fitted, damaged rubber
mounts can cause
knocking noises.
NumberDesignationModel 129Model 170Model 202
BE32.25-P-1001- Oil reserve check mm0+20+20+2

2001 Mercedes-Benz ML320
1998-2005 SUSPENSION Suspension - 163 Chassis
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Saturday, October 02, 2010 3:37:36 PMPage 20 © 2006 Mitchell Repair Information Company, LLC.

Test values for shock absorber
Test values for shock absorber
REMOVE/INSTALL SHOCK ABSORBER ON SPRING STRUT - AR32.25-P-0200-07GH
Use only approved tensioning devices; additionally shield off hazardous area if necessary.
Check special tools for damage and correct operation, (visual inspection). Wear protective gloves.
Rear axle shock absorber
Fig. 19: Identifying Tensioning Device (203 589 01 31 00)
02A(shock absorber
when new)
BE32.25-P-1002-
02AOil reserve check
(shock absorber
when used)mm< or =20< or =20< or =20
NumberDesignationModel 208Model 210Model 211
BE32.25-P-1001-
02AOil reserve check
(shock absorber
when new)mm0+20+20+2
BE32.25-P-1002-
02AOil reserve check
(shock absorber
when used)mm< or =20< or =20< or =20
NumberDesignationModel 230
BE32.25-P-1001-02AOil reserve check (shock
absorber when new)mm0+2
BE32.25-P-1002-02AOil reserve check (shock
absorber when used)mm< or =20
NumberDesignationModel Series 163
BA32.25-P-1003-03DSelf-locking nut, shock
absorber to rear springNM30

2001 Mercedes-Benz ML320
1998-2005 SUSPENSION Suspension - 163 Chassis
me
Saturday, October 02, 2010 3:37:36 PMPage 21 © 2006 Mitchell Repair Information Company, LLC.

Fig. 20: Identifying Tensioning Plates (163 589 00 63 00)
1. Pre-equip tensioning device.
Insert tensioning plates (01a) into tensioner (01) until they engage. Press pins (arrows) to remove the
clamping plates.
2. Pre-adjust tensioning device to approx. 130 mm (a). This makes it easier to insert the rear spring
Fig. 21: Identifying Tensioning Plates And Pins

3. Clamp tensioning device (01) horizontal in vise.
4. Insert rear spring (73) in the clamping plates (01) so that the end of the winding of the rear spring is
roughly parallel with the upper edge of the clamping plates (arrows).
Insert rear spring from the 5th to the 11th rear spring winding (counted from the side with the larger
winding diameter in the clamping plates (6 to 7 windings must be clamped).

2001 Mercedes-Benz ML320
1998-2005 SUSPENSION Suspension - 163 Chassis
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Saturday, October 02, 2010 3:37:36 PMPage 22 © 2006 Mitchell Repair Information Company, LLC.

Fig. 22: Clamping Tensioning Device Horizontal In Vise
5. 73Rotate rear spring (73)by approx. a quarter of a revolution (counterclockwise) so that the end of the
rear spring winding is located approximately in the center of the clamping plate (arrow a).
6. Check whether the lugs of the clamping plates are located above the rear spring windings (arrow b), if
necessary correct the position of the rear spring.
7. Mark the position of the rear spring (73) relative to the support bearing (73d) and rear spring guide (73h)
(arrow c).
Installation: When the rear spring is relieved of load the markings applied must align.
Fig. 23: Identifying Tensioning Device Horizontal In Vise

2001 Mercedes-Benz ML320
1998-2005 SUSPENSION Suspension - 163 Chassis
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When replacing the rear spring, support bearing or rear spring guide, the markings from the old
components must be taken over.
8. Compress rear spring.
9. Unscrew nut (73a) of the upper shock absorber mounting, counterholding the piston rod in the process.
10. Remove plate (73b), upper rubber mount (73c), support bearing (73d) and spring guide (73h)
Installation: Pay attention to correct position of components.
11. Pull out shock absorber and remove lower rubber mount (75c), sleeve (75y), plate (75g) and protective
sleeve (75f).
Installation: Pay attention to correct position of components.
12. Install in reverse sequence.
Fig. 24: Identifying Plate, Upper Rubber Mount, Support Bearing And Spring Guide

REMOVE/INSTALL REAR SPRING STRUT - AR32.25-P-1016GH
MODEL 163.113 /128 /136 /154 /157 /172 /174 /175

2001 Mercedes-Benz ML320
1998-2005 SUSPENSION Suspension - 163 Chassis
me
Saturday, October 02, 2010 3:37:36 PMPage 24 © 2006 Mitchell Repair Information Company, LLC.

Fig. 25: Identifying Rear Spring Strut Components
Remove/Install
Notes on self-locking nuts
and boltsAll modelsAH00.00-N-0001-01A
1Remove rear wheels
Remove/install wheels,
rotate if necessary AP40.10-P-4050GH
2.1Remove spare wheel Except with spare
wheel holder/spare wheel,
code 849 and model
163.174 (vehicle with
auxiliary fuel tank).
3.1Remove spare wheel
holder Except with spare
wheel holder/spare wheel,
code 849 and model
163.174 (vehicle with
auxiliary fuel tank).
Pull out locking pin.
Remove spare wheel
bracket from side rail.
4.1Remove wheel housing
lining On model 163.174
(vehicle with auxiliary
fuel tank).
5Pull off cover (75p) Installation: Pay
attention to correct

2001 Mercedes-Benz ML320
1998-2005 SUSPENSION Suspension - 163 Chassis
me
Saturday, October 02, 2010 3:37:36 PMPage 25 © 2006 Mitchell Repair Information Company, LLC.