Removal and installation of the rear axle assembly (Mercedes-Benz M-Class W163)

Note: All self-locking bolts and nuts must be replaced!

1. The details of the rear axle assembly installation are shown in the illustrations to which all references in the text refer.

2. Remove the rear wheels.

3. On models 163.174 (ML 55 AMG), empty the fuel tank (see Chapter Emptying the fuel tank), tie the additional tank to the longitudinal beam.

4. Disconnect the brake line (111h) from the flexible hose (111e).

5. Remove the brake hose/cable support brackets (111f) from the frame cross members.

6. Remove the wheel sensors (L6/3, L6/2).

7. If equipped, remove the exhaust system shield from the rear axle subframe (1).



8. On the right front side of the shield, unbolt the parking brake cable support bracket (1h).

9. Release the rear differential crankcase ventilation hose (55) from the retainer on the fuel tank, - except models 163.174 (ML 55 AMG).

10. Loosen the nut of the bolt securing the longitudinal fuel tank mounting bracket to the subframe (109).

11. Disconnect the rear parking brake cables (112a) from the adjuster (110b) (see Chapter Brake and auxiliary systems).

12. Release the cable assemblies (112a) from the intermediate clamps on the frame.

13. Remove the cable assembly support bracket (112b) installed on the left side of the floor panel.

14. Disconnect the propeller shaft (106) from the rear differential and tie it to the frame.

15. Disconnect the control link (1p) from the subframe (1).

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16. On models equipped with xenon headlights, disconnect the ride height control rod (120a) from the upper support.

17. Remove the strut assembly (6j) from the lower control arm.

18. Press the upper ball joint (91a) out of the hub assembly.

19. Support the rear differential assembly using a special tool.

20. Remove the subframe mounting bolts (1c and 1d) and carefully lower the rear axle assembly, being careful not to pinch the brake cables and tubes.

Note: On models 163.174 (ML 55 AMG), first lower the axle assembly and release the differential ventilation hose (55) from the retainer on the wall of the additional fuel tank.

21. Inspect the assembly components for signs of damage, replace any faulty parts.



22. If necessary, disconnect from the longitudinal beams and remove the strut assemblies (6j) or the upper wishbones (91).

23. Also, if necessary, remove the subframe and replace the rubber cushions of the differential suspension supports; the bushings are removed/installed using a special extractor.

24. Installation is carried out in the reverse order - before installation, carefully clean the mating surfaces of the bridge (1) and longitudinal beams, if necessary, eliminate surface deformations, also run a tap through the bolt holes in the floor panel for the subframe mounting bolts (1c and 1d). Make sure that the guide pins (a) fall into the receiving holes in the beams. Final tightening of the transverse arm fastening elements (if you filmed) is carried out only after lowering the car to the ground, - when installing, ensure that the bridge assembly occupies a strictly horizontal position, take care of the correct alignment of the landing marks on the beams (b). Do not forget about the need to replace the sealing elements of the nipple connectors of the hydraulic lines.

25. Finally, adjust the working fluid level and bleed the brake system (see Chapter Brake and auxiliary systems), check the oil level in the differential.

26. Correct the direction of the optical axes of the headlights and adjust the suspension geometry (see Section Suspension Geometry).