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How to change front ball joint on Mercedes ML W163 – replacement guide

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Important!

This replacement procedure can be used for:
MERCEDES-BENZ M-Class (W163) ML 320 (163.154), MERCEDES-BENZ M-Class (W163) ML 230 (163.136), MERCEDES-BENZ M-Class (W163) ML 430 (163.172), MERCEDES-BENZ M-Class (W163) ML 55 AMG (163.174), MERCEDES-BENZ M-Class (W163) ML 400 CDI (163.128), MERCEDES-BENZ M-Class (W163) ML 500 (163.175), MERCEDES-BENZ M-Class (W163) ML 350 (163.157), MERCEDES-BENZ M-Class (W163) ML 350 … View more

The steps may slightly vary depending on the car design.

How to change front ball joint on MERCEDES ML W163 [TUTORIAL AUTODOC]

Alternative products

Ball Joint

Replacement: ball joint – Mercedes ML W163. List of the tools you'll need:

                      Wire brush
                    
                      WD-40 spray
                    
                      Sealant
                    
                      All-purpose cleaning spray
                    
                      Brake cleaner 
                    
                      Multipurpose grease
                    
                      Copper grease 
                    
                      Torque wrench
                    
                      Combination spanner #12
                    
                      Combination spanner #19
                    
                      Combination spanner #22
                    
                      Drive socket # 10 
                    
                      Drive socket # 12 
                    
                      Drive socket # 22 
                    
                      Drive socket # 36 
                    
                      HEX bit No.H5
                    
                      Wheel impact socket #17
                    
                      Ratchet wrench
                    
                      Pin wrench socket
                    
                      Ball joint puller
                    
                      Flat Screwdriver
                    
                      Pin punch
                    
                      Hammer
                    
                      Tap wrench
                    
                      Rubber mallet
                    
                      Impact screwdriver
                    
                      Bush and bearing driver set
                    
                      Hydraulic transmission jack
                    
                      Crow bar
                    
                      Wheel chock

Buy tools

Replacement: ball joint – Mercedes ML W163. Tip from AUTODOC experts:

The replacement procedure is identical for the left and right ball joints.
Please note: all work on the car – Mercedes ML W163 – should be done with the engine switched off.

Carry out replacement in the following order:

Step 1

Secure the wheels with chocks.

Step 2

Loosen the wheel mounting bolts. Use wheel impact socket #17.
Step 3

Raise the front of the car and secure on supports.
Step 4

Unscrew the wheel bolts.

AUTODOC recommends:
Warning! To avoid injury, hold the wheel while unscrewing the fastening bolts. Mercedes ML W163
Step 5

Remove the wheel.
Step 6

Loosen the fastener of the driveshaft. Use a drive socket #36. Use a tap wrench.
Step 7

Remove the fastening nut.
Step 8

Treat the splines of the driveshaft CV joint. Use WD-40 spray.
Step 9

Detach the driveshaft from the steering knuckle. Use a pin punch. Use a hammer.

Replacement: ball joint – Mercedes ML W163. AUTODOC experts recommend:
Make sure that the drive shaft is not unloaded (when the car is jacked).
Step 10

Clean the ABS wiring harness bracket. Use a wire brush. Use WD-40 spray.
Step 11

Detach the ABS wiring harness bracket. Use a drive socket #10. Use a ratchet wrench.
Step 12

Spread the brake pads. Use a crowbar.
Step 13

Clean the brake caliper bracket fasteners. Use a wire brush. Use WD-40 spray.
Step 14

Unscrew the caliper bracket fastening. Use a drive socket #22. Use a ratchet wrench. Use a tap wrench.
Step 15

Remove the brake caliper together with its bracket.

Replacement: ball joint – Mercedes ML W163. Professionals recommend:
Tie the caliper to the suspension or to the body with a wire without disconnecting from the brake hose to prevent depressurization of the brake system.Make sure that the brake caliper is not hanging on the brake hose.Don't press the brake pedal after the brake caliper has been removed. As a result, the piston can fall out from the brake cylinder, and brake fluid leakage and depressurization of the system may occur. Check the brake caliper bracket, brake caliper guide pins and boots. Clean them. Replace, if necessary.
Step 16

Disconnect the ABS sensor wiring.
Step 17

Clean the fastener connecting the ball joint to the steering knuckle. Use a wire brush. Use WD-40 spray.
Step 18

Unscrew the fastener that connects the ball joint of the upper arm to the steering knuckle. Use a combination spanner #19.
Step 19

Detach the upper arm ball joint from the steering knuckle. Use a ball joint puller.
Step 20

Clean the brake disc fastener. Use a wire brush. Use WD-40 spray.
Step 21

Unscrew the brake disc fastening. Use HEX No.H5. Use an impact screwdriver.
Step 22

Remove the brake disc. Use a rubber mallet.
Step 23

Clean the fasteners of the brake disc cover. Use a wire brush. Use WD-40 spray.
Step 24

Unscrew the fasteners of the brake disc cover. Use a combination spanner #12.
Step 25

Remove the brake disc cover.
Step 26

Clean the fastener connecting the ball joint to the steering knuckle. Use a wire brush. Use WD-40 spray.
Step 27

Unscrew the ball joint fastening to the steering knuckle. Use the pin wrench socket. Use a tap wrench.
Step 28

Clean the fastener connecting the tie rod end to the steering knuckle. Use a wire brush. Use WD-40 spray.
Step 29

Unscrew the end fastening nut to the steering knuckle. Use a drive socket #22. Use a ratchet wrench.
Step 30

Disconnect the tie rod end from the steering knuckle. Use a ball joint puller.
Step 31

Prop up the steering knuckle. Use a hydraulic transmission jack.
Step 32

Clean the ABS sensor fastener. Use a wire brush. Use WD-40 spray.
Step 33

Unscrew the fastener connecting the ABS sensor to the steering knuckle. Use a drive socket #10. Use a ratchet wrench.
Step 34

Disconnect the ABS sensor.
Step 35

Clean the fastener connecting the ball joint to the steering knuckle. Use a wire brush. Use WD-40 spray.
Step 36

Unscrew the fastener that connects the ball joint of the lower arm to the steering knuckle. Use a combination spanner #22.
Step 37

Remove the support from under the steering knuckle.

AUTODOC recommends:
Replacement: ball joint – Mercedes ML W163. Lower the transmission jack smoothly, without jerks, to avoid damaging components and mechanisms.
Step 38

Support the arm. Use a hydraulic transmission jack.
Step 39

Detach the upper control arm from the steering knuckle.
Step 40

Detach the lower arm ball joint from the steering knuckle. Use a ball joint puller.

Step 41

Remove the steering knuckle together with the ball joint. Use a ball joint puller.
Step 42

Clean the ball joint mounting seat. Use a wire brush. Use WD-40 spray.
Step 43

Remove the ball joint from the steering knuckle. Use a bush and bearing driver set.
Step 44

Clean the ball joint mounting seat. Use a wire brush. Use WD-40 spray.
Step 45

Install the ball joint on the steering knuckle. Use a bush and bearing driver set.
Step 46

Screw the fastener connecting the ball joint to the steering knuckle. Use the pin wrench socket. Use a tap wrench.
Step 47

Unscrew the ball joint fastening to the steering knuckle. Use the pin wrench socket. Use a tap wrench.
Step 48

Clean the ball joint fasteners. Use all-purpose cleaning spray.
Step 49

Treat the fasteners of the ball joint. Use a sealant.
Step 50

Tighten the fastener connecting the ball joint to the steering knuckle. Use the pin wrench socket. Use a torque wrench. Observe the recommended tightening torque.
Step 51

Clean the splines of the drive shaft CV joint. Use a wire brush. Use WD-40 spray.
Step 52

Clean the steering knuckle mounting seats. Use a wire brush. Use WD-40 spray.
Step 53

Install the steering knuckle together with the ball joint.
Step 54

Install the drive shaft.
Step 55

Attach the upper control arm to the steering knuckle.
Step 56

Connect the tie rod end to the steering knuckle.
Step 57

Screw on the fastening nut that connects the tie rod end to the steering knuckle. Use a drive socket #22. Use a ratchet wrench.
Step 58

Connect the upper arm ball joint to the steering knuckle.

Step 59

Screw in the fastener that connects the upper arm ball joint to the steering knuckle. Use a combination spanner #19.
Step 60

Connect the lower arm ball joint to the steering knuckle.

Step 61

Screw in the fastener that connects the lower arm ball joint to the steering knuckle. Use a combination spanner #22.
Step 62

Tighten the fastener that connects the lower arm ball joint to the steering knuckle. Use a combination spanner #22. Use a torque wrench. Tighten it to 85 Nm torque.
Step 63

Tighten the fastener that connects the upper arm ball joint to the steering knuckle. Use a combination spanner #19. Use a torque wrench. Tighten it to 50 Nm torque.
Step 64

Tighten the fastening nut connecting the tie rod end to the steering knuckle. Use a drive socket #22. Use a torque wrench. Tighten it to 55 Nm torque.
Step 65

Remove the support from under the arm.

AUTODOC recommends:
Mercedes ML W163 – Do not lower the transmission jack sharply to avoid damaging components and mechanisms of the car.
Step 66

Clean the ABS sensor mounting seat. Use a wire brush. Use WD-40 spray.
Step 67

Treat the ABS sensor fastener. Use a multipurpose grease. Use a flat screwdriver.
Step 68

Connect the ABS sensor.
Step 69

Tighten the fastener that connects the ABS sensor to the steering knuckle. Use a drive socket #10. Use a torque wrench. Tighten it to 7 Nm torque.
Step 70

Install the brake disc cover.
Step 71

Screw in the fasteners of the brake disc cover. Use a drive socket #12. Use a torque wrench. Tighten it to 9 Nm torque.
Step 72

Clean the hub. Use a wire brush. Treat the contacting surface. Use copper grease.
Step 73

Install the fastening nut.
Step 74

Screw in the nut of the CV axle. Use a drive socket #36.
Step 75

Install the brake disc.
Step 76

Tighten the brake disc fastening. Use HEX No.H5. Use a torque wrench. Tighten it to 8 Nm torque.
Step 77

Install the brake caliper together with its bracket.
Step 78

Tighten the brake caliper bracket. Use a drive socket #22. Use a torque wrench. Tighten it to 180 Nm torque.
Step 79

Fasten the ABS wiring harness bracket. Use a drive socket #10. Use a torque wrench. Tighten it to 13 Nm torque.
Step 80

Connect the ABS sensor wiring.
Step 81

Treat the steering knuckle fasteners. Use copper grease.
Step 82

Tighten the drive shaft nut. Use a drive socket #36. Use a torque wrench. Observe the recommended tightening torque.
Step 83

Clean the wheel rim mounting seat. Use a wire brush.
Step 84

Treat the surface where the brake disc contacts the wheel rim. Use copper grease.
Step 85

Clean the brake disk surface. Use a brake cleaner.

AUTODOC recommends:
Replacement: ball joint – Mercedes ML W163. After applying the spray, wait a few minutes.
Step 86

Install the wheel.

AUTODOC recommends:
Important! Hold the wheel while screwing in the fastening bolts. Mercedes ML W163
Step 87

Screw in the wheel bolts. Use wheel impact socket #17.
Step 88

Lower the car and working in a cross order, tighten the wheel bolts. Use wheel impact socket #17. Use a torque wrench. Tighten it to 150 Nm torque.

Step 89

Remove the jacks and chocks.

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