1997 MERCEDES-BENZ ML320 steering

1998-2005 DRIVELINE/AXLES
Front Axle - 163 Chassis
TESTING & REPAIR
TESTING AND REPAIR WORK: PASSENGER CARS: FRONT AXLE - AR33.00-Z-9163AA
MODEL 163
ATTACH ENGINE SUPPORT BRACKET AND RAISE ENGINE - AR33.10-P-0100-01BV
Workshop equipment
Removing and installing front axleMODELS
163.113 /128 /136 /154 /157 /172 /174 /175AR33.10-P-
0100GH
Remove/install rubber bushes of front
axle transmission mountingMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.10-P-
0120GH
Remove/install front axle halfMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.10-P-
0200GH
Remove/install front axle shaft flange
and double-row angular ball bearingMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.20-P-
0315GH
Checking follower joint of steering
knuckle mount (installed)MODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.20-P-
0426GH
Replace supporting jointMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.20-P-
0440GH
Removing and installing upper
wishboneMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.20-P-
0500GH
Remove/install lower wishboneMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.20-P-
0510GH
Replace front bearing of lower
wishboneMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.20-P-
0526GH
Removing and installing steering
knuckleMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.25-P-
0400GH
Remove/install front axle gearMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.30-P-
0525GH
Replace shaft seal on drive pinionMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.30-P-
0530GH
Remove/install radial shaft seal at front
axle gear of front axle shaftMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.30-P-
0545GH
Remove/install front axle shaftsMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.30-P-
0620GH
Replace rubber boots on front axle shaftMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.30-P-
0660GH
WE58.40-Z-1007-11AEngine lifting fixture

2001 Mercedes-Benz ML320
1998-2005 DRIVELINE/AXLES Front Axle - 163 Chassis

2001 Mercedes-Benz ML320
1998-2005 DRIVELINE/AXLES Front Axle - 163 Chassis
me
Saturday, October 02, 2010 3:38:21 PMPage 1 © 2006 Mitchell Repair Information Company, LLC.
me
Saturday, October 02, 2010 3:38:25 PMPage 1 © 2006 Mitchell Repair Information Company, LLC.

brake hoses *BA42.10-P-1001-04A
Ring wrench socketFig. 5
5Unbolt propeller shaft at
flange on front axle
transmission *BA41.20-P-1001-01A
6Remove left and right
front springs AR32.20-P-0200GH
7.1Remove lower engine
compartment panelingModel
163.157 /172 /174 /175AR61.20-P-1105GH
Model 163.113/ 128AR94.30-P-5400GH
8Detach torsion bar (28) at
vehicle frame *BA32.20-P-1001-02G
9Detach upper transverse
control arm (6) from
vehicle frame Installation: Tighten
new nuts slightly. Tighten
bolt fully only when
vehicle is on its wheels and
ready to drive.
*BA33.20-P-1006-01D
10Detach bracket for oil
lines from transmission to
oil cooler on front axle
carrier
11Unclip brake line at rear
of front-axle
crossmember
12.1Remove vehicle level
controller connecting rod
(95b) at lower transverse
control arm on right Vehicles with xenon
headlamps.
13Extract fluid from power
steering pump reservoir Hand pumpFig. 6
14Turn steering wheel to
center position (front
wheels in straight-ahead
position) and secureThe steering wheel must
not be turned when the
steering coupling has been
removed. This will damage
the fanfare horns and airbag
clock spring contact
beyond repair.
Remove ignition key
and turn steering wheel so
that it locks.
15.1Detach plug-in connector
for speed-sensitive power
steering to timing case Vehicles with speed-
sensitive power steering
only.

2001 Mercedes-Benz ML320
1998-2005 DRIVELINE/AXLES Front Axle - 163 Chassis
me
Saturday, October 02, 2010 3:38:21 PMPage 5 © 2006 Mitchell Repair Information Company, LLC.

16Unscrew nut (25d) and
bolt from steering
coupling (25) and pull
lower steering shaft (80a)
up out of steering
coupling (25) Do not use force as the
corrugated tube is sensitive
to lateral forces. Enlarge
clamping groove a little
with a screwdriver if
necessary.
Installation: ?
Turn rack-and-pinion
steering (23) to center
position, install steering
coupling (25).
Replace self-locking
nuts (25d).AR46.20-P-0600-01GH
*BA46.10-P-1001-01D
17Unscrew return line (30f)
and high-pressure
expansion hose (30i) Connecting fitting or
banjo bolts depending on
the version.
Seal off line connections
with plugs.
Installation: Replace
sealing rings.
Return line connection
fitting: ?

High pressure expansion
hose connection fitting: ?*BA46.20-P-1001-01D

Return line banjo bolt: ?*BA46.20-P-1002-01D

High pressure expansion
hose connection fitting: ?*BA46.20-P-1004-01D
*BA46.20-P-1005-01D
18Detach bleeding and
venting hose from
differential
19Prop front axle carrier (1)
with pit or installation lift Use assembly adapter.AR33.10-P-0100-03GH
*WE58.40-Z-1019-11A
20Unscrew bolts (1f) from
front axle carrier (1) The bolts (1f)are self-
tapping, so the following
points must be observed:
Never re-tap thread
in side member.
Replace bolts.


2001 Mercedes-Benz ML320
1998-2005 DRIVELINE/AXLES Front Axle - 163 Chassis
me
Saturday, October 02, 2010 3:38:21 PMPage 6 © 2006 Mitchell Repair Information Company, LLC.

Front axle carrier
Wheel control, hub
Front axle torsion strut
Propeller shaft of front axle gear
Use original bolts
only.
Do not position bolts
at an angle when
screwing in.
Do not use an impact
wrench.
Observe the
tightening torque.
*BA33.10-P-1001-01C
21Lower front axle carrier
(1), pushing all hoses to
one side Installation: Contact
surfaces of front axle
carrier to longitudinal
member must be cleaned
and flat.
Insert the locating pins of
the front axle carrier into
the holes in the side
member.
22Check front axle carrier
(1) for damage
23Install in the reverse order
24Fill power steering pump
and bleedEngine 112, 113AR46.30-P-0010B
Engine 111, 612AR46.30-P-0010P
25Bleed brake system AR42.10-P-0010GH
26Perform chassis
alignment AR40.20-P-0200GH
NumberDesignationModel Series 163
BA33.10-P-1001-01CBolt of front axle carrier to frameNm200
NumberDesignationModel Series 163
BA33.20-P-1006-01DBolt, upper transverse control arm to frameNm120
NumberDesignationModel Series 163
BA32.20-P-1001-02GBolt, retaining bracket to frameNm100
NumberDesignationModel Series 163

2001 Mercedes-Benz ML320
1998-2005 DRIVELINE/AXLES Front Axle - 163 Chassis
me
Saturday, October 02, 2010 3:38:21 PMPage 7 © 2006 Mitchell Repair Information Company, LLC.

Brake lines, brake hoses
Brake lines, brake hoses
Steering shaft
Steering gear
BA41.20-P-1001-01ASelf-locking bolt of propeller shaft to front-axle gear flangeNm40
NumberDesignationModel
163.128/172/174/175Type 163.136Model
163.154/157
BA42.10-P-
1001-04ABrake pipe to
brake hoseNm181818
NumberDesignationModel 163.113 as
of VIN A289565,
X754620 163.154 as
of VIN A289565
except Model 163.113 to
VIN A289564,
X754619 163.154 to
VIN A289564
BA42.10-P-1001-
04ABrake pipe to brake
hoseNm1818
NumberDesignationModel Series
163
BA46.10-P-1001-
01DSelf-locking nut of steering coupling to steering shaft and rack-
and-pinion steeringNm28
NumberDesignationModel 163 up to
VIN A289559,
X754619Model 163 as of
VIN A289560,
X754620
BA46.20-P-1001-
01DScrew joint, return
line connection
fitting to rack-and-
pinion steeringNm1515
BA46.20-P-1002-
01DScrew joint, high-
pressure expansion
hose connection
fitting to rack-and-
pinion steeringNm1515
BA46.20-P-1004-
01DHollow-core screw
from return line to
rack-and-pinion
steeringNm3030
BA46.20-P-1005-
01DBanjo bolt of high-
pressure stretch hose
to rack-and-pinion
steeringNm3030

2001 Mercedes-Benz ML320
1998-2005 DRIVELINE/AXLES Front Axle - 163 Chassis
me
Saturday, October 02, 2010 3:38:21 PMPage 8 © 2006 Mitchell Repair Information Company, LLC.

Box wrench bitFig. 5
8Detach track rod (10)
from steering knuckleCheck rubber boot and
ball joint for wear and
damage.AR46.40-P-0200-02C
*BA46.40-P-1001-01C
Thrust pieceFig. 16
PullerFig. 17
9.1Detach link rod of level
controller (95b) from
lower transverse control
arm on right-hand side Vehicles with xenon
headlamps.
10Detach upper transverse
control arm (6) from
vehicle frame Installation: Tighten
new nuts slightly until
they touch.
Only tighten the bolt
when the vehicle is on its
wheels in ready-to-drive
condition.
*BA33.20-P-1006-01D
11Press front axle shaft out
of front axle shaft flange AR33.30-P-0620-04GH
Removal and
installation toolFig. 18
12Support front axle half at
lower transverse control
arm with inspection pit or
assembly lift
13Detach torsion bar (28)
from lower transverse
control arm *BA32.20-P-1002-02G
14Detach lower transverse
control arm (4) from front
axle carrieri004 Installation:
Tighten new nuts slightly
until they touch.
Only tighten the bolt
when the vehicle is on its
wheels in ready-to-drive
condition.
*BA33.20-P-1004-01D
15Loosen clamped joint at
rear of lower transverse
control arm (4) and fold
down bearing shell (4d) Installation: Tighten
new nuts slightly until
they touch.
Only tighten the bolt
when the vehicle is on its
wheels in ready-to-drive
condition.

2001 Mercedes-Benz ML320
1998-2005 DRIVELINE/AXLES Front Axle - 163 Chassis
me
Saturday, October 02, 2010 3:38:22 PMPage 14 © 2006 Mitchell Repair Information Company, LLC.

Front axle torsion bar
Wheel location, hub
Front axle shaft
Brake lines, brake hoses
Brake lines, brake hoses
Track rod
*BA33.20-P-1005-01D
16Install in the reverse order
17Bleed brake system AR42.10-P-0010GH
18Carry out chassis
alignment check. AR40.20-P-0200GH
NumberDesignationModel 163
BA32.20-P-1002-02GBolt, torsion bar to transverse control armNm68
NumberDesignationModel 163
BA33.20-P-1004-01DBolt, lower transverse control arm at front to front axle carrierNm135
BA33.20-P-1005-01DBolt, lower transverse control arm at rear to front axle carrierNm30
BA33.20-P-1006-01DBolt, upper transverse control arm to frameNm120
NumberDesignationModel 163
BA33.30-P-1001-02BNut, front axle shaft to front axle shaft flangeNm490
NumberDesignationModel 163.113 as
of VIN A289565,
X754620 163.154 as
of VIN A289565Model 163.113 to
VIN A289564,
X754619 163.154 to
VIN A289564
BA42.10-P-1001-
04ABrake line to brake
hoseNm1818
NumberDesignationModel
163.128 /172 /174 /175Model
163.136Model
163.154 /157

BA42.10-P-1001-
04ABrake line to brake
hoseNm181818
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 15 © 2006 Mitchell Repair Information Company, LLC.

Fig. 31: Identifying Front Axle Shaft Flange And Double-Row Angular Ball Bearing Components
Modification notes
7.8.00Pulling out front axle
shaft flange, changed
Step 2:
The front axle shaft flange is now pulled out using a
stationary press and not with the auxiliary hydraulic
press.
AR33.20-P-
0315-01GI

Remove/Install
1Remove steering knuckle AR33.25-P-
0400GH
2Pull out front axle shaft flange (9)
AR33.20-P-
0315-01GI
Extractor toolFig. 19
Extraction and insertion toolFig. 20
3Detach circlip (9p)
Installation: Ensure that the circlip
seats securely in the wheel carrier.
Pliers for locking ring*WH58.30-Z-
1009-02A
4Pull double-row angular ball bearing
(9n) out of steering knuckle AR33.20-P-
0315-03GH
Extraction and insertion toolFig. 20
AR33.20-P-
0315-04GH

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