Mercedes W163 Rear Brake Pads and Rotors Replacement

Step-by-step instructions on how to replace the rear brake pads and rotors on any Mercedes-Benz ML320, ML430, ML350, ML500, years 1998-2005

If this is your first time doing this job, plan on spending around 4 hours. Make sure you have all your tools and parts ready. We strongly recommend installing ceramic brake pads and new rotors. Use quality brake pads that match the vehicle VIN and brake package. Ceramic pads can reduce dust and noise, but braking characteristics vary by manufacturer and pad compound. We can go on and on talking about ceramic brake pads. You can get ceramic pads for almost the same price as semi-metallic ones. You can get new rotors and ceramic brake pads for under $100. How? If you need a hint, check out this link.

Application: ML320, ML430, ML500, ML350, ML55

Years: 1998, 1999, 200,0 20,01 2,002,2003, 2004, 2005

Parts Needed:

Notes before you start.

Ensure no mineral oil, grease, or other substances enter the brake system.
If the vehicle has been in a severe impact, Mercedes calls for replacement when the hydraulic unit itself has received a heavy blow or shows evidence such as damaged lines, leaking connections, damaged wiring, visible block damage, or displacement from its bracket
Avoid using hammers. Do not remove the brake caliper with a hammer, pliers, levers, or similar tools.
When removing or installing the wheel, be careful not to bend the dust shield on the back of the rotor. If you bend it, you will hear a scratching noise when you put everything back together and start driving. If you bend the dust shield on the back of the rotor, you will need to remove the wheel and bend the shield away so it doesn’t touch the rotors.
Make sure to use your jack and a jack stand. A nice set of jack stands costs around $20 on Amazon.
If you were driving the car before working on it, be careful, as the rotors will be hot.
Do not disconnect the brake hose for this repair. Support the caliper so the hose is not stretched. If a brake hose is opened, bleed the brake system and check carefully for leaks before driving.

Step-by-step instructions.

Loosen your lug nuts; do not remove them yet.
Jack up the car. Make sure to secure it with jack stands.
Release the parking brake. Since you will be removing the rotors, you must ensure the parking brakes are loose. Otherwise, you cannot remove the rotors without damaging the brake shoes. If you need to replace the rear brake shoes as well, check out remove and install emergency brake shoes M-Class W163
Remove the brake fluid reservoir cap.
Remove the bolts on the rear of the brake caliper.
Remove the brake caliper. Make sure you secure the caliper. Don’t let it hang or put pressure on the hydraulic brake hose.
Remove the support plate.
Remove the security bolt. Mercedes specifically says to back off the parking brake adjustment mechanism if the drum has worn in; otherwise, the parking brake shoes can be damaged.
Remove the rear rotor. Make sure you have your parking/emergency brakes released.
Install new rotor. Clean the surface where the rotors sit. Clean the hub and rotor contact surfaces. Apply only a light film of suitable grease to the rotor centering seat. Keep grease off the rotor friction surfaces and wheel bolt seats.
Install the locking bolt and tighten it to 23 Nm.
Install new brake pads on the calipers. First, you must install the inner brake pad into the piston. Then install the outer brake pad. Make sure to clean the surfaces where the brake pads slide. You will need to press the cylinder in the caliper. You will need a caliper press for this. Fixed W163 calipers use retaining pins and a retaining spring, with the pads pulled from the fixed caliper. Ensure you install a new brake wear sensor if your old one is worn out.
Install the caliper. Tighten the two bolts in the back of the caliper to 23 Nm. Note that Mercedes specifies 115 Nm for the rear fixed caliper to wheel carrier bolts. WIS also calls for replacement of the self-locking fixed caliper bolts. Identify the caliper type before stating a torque.
Reinstall the rest in reverse order. W163 wheel bolts are specified at 150 Nm
Remember to put the cap back on the brake fluid reservoir.
Start the car but do not drive yet. Before driving, press the brake pedal several times until it feels firm. Check the brake fluid level and correct it if necessary. Confirm normal brake operation before returning the vehicle to the road.