2002 MERCEDES-BENZ ML500 Brake Service (ONLINE REPAIR MANUALS)

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BRAKE SERVICE PROCEDURES FOR 2002 MERCEDES-BENZ ML500 AUTOMOBILES

Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported 2002 MERCEDES-BENZ ML500 cars and light trucks from 1990+.

Disc Brakes -> Precautions -> Battery Ground Cable
Vehicle: 2002 MERCEDES-BENZ ML500 5.0 V8 GAS

Battery Ground Cable

Prior to service, dis...

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BRAKE SERVICE PROCEDURES FOR 2002 MERCEDES-BENZ ML500 AUTOMOBILES

Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported 2002 MERCEDES-BENZ ML500 cars and light trucks from 1990+.

Power Brake Units -> Power Brake Unit Service -> Brake Booster, Replace -> CL55, CL500, CL600, S55, S430, S500 & S600 -> CLK55, CLK320, CLK430 & CLK500 -> E55, E320, E430, E500, SL55, SL500, SL600, SLK32, SLK230 & SLK320
Vehicle: 2002 MERCEDES-BENZ ML500 5.0 V8 GAS

Brake Booster, Replace

E55, E320, E430, E500, SL55, SL500, SL600, SLK32, SLK230 & SLK320
  • Remove master cylinder as outlined in "Hydraulic Brake Systems."
  • Inspect master cylinder rear piston for leaks. If no leaks are visible, proceed as follows:
    • Remove and measure brake fluid in booster.
    • If there is more than 3.38 ounces of brake fluid, booster must be replaced.
  • Disconnect vacuum line at booster.
  • Remove cover below instrument panel.
  • Disconnect brake pedal return spring.
  • Disconnect pedal locking device and remove pin.
  • Remove carrier mounting nuts.
  • Remove brake booster. Do not damage ...

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BRAKE SERVICE PROCEDURES FOR 2002 MERCEDES-BENZ ML500 AUTOMOBILES

Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported 2002 MERCEDES-BENZ ML500 cars and light trucks from 1990+.

Disc Brakes -> Caliper Service -> Assemble -> Disassemble -> Fixed -> Floating -> Front -> Inspection -> Rear
Vehicle: 2002 MERCEDES-BENZ ML500 5.0 V8 GAS

Front

Fixed
Disassemble
  • Press off dust cap
  • Insert 1.1025 inches thick metal segment (brake disc section) into fixed caliper and carefully force pistons out against stop with compressed air.
  • Remove piston using piston-turning pliers tool No. 000 589 50 37 00, or equivalent.
  • Remove piston seal from groove in cylinder bore.
Inspection
  • If piston is stuck or there are scores or rusted bores, replace complete caliper.
  • Remove deposits on piston with soft brass wire brush or rough cloth only. If there is noticeable damage to chrome plating, replace piston.
  • Inspect pistons and bores in fixed calip...

CLICK HERE TO GET FULL ACCESS TO 2002 MERCEDES-BENZ ML500 BRAKE SERVICE PROCEDURES

BRAKE SERVICE PROCEDURES FOR 2002 MERCEDES-BENZ ML500 AUTOMOBILES

Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported 2002 MERCEDES-BENZ ML500 cars and light trucks from 1990+.

Disc Brakes -> Parking Brake Service -> Foot Control Cable, Replace -> Foot Control, Replace -> Hand Lever, Replace -> Parking Brake Rear Control Cable, Replace -> Parking Brake Shoes, Replace -> SLK32, SLK230 & SLK320
Vehicle: 2002 MERCEDES-BENZ ML500 5.0 V8 GAS

Foot Control, Replace

  • On SL55, SL500 and SL600 models, remove exhaust system heat shield.
  • On E55, E320, E430 and E500 models, remove cover panel under rear squab.
  • On CLK55, CLK320, CLK430, CLK500, E55, E320, E430 and E500 models, proceed as follows:
    • Turn preloading automatic slack adjuster eccentric pin clockwise approximately one turn using suitable Allen wrench through cover sheet oblong hole.
    • At same time, push pin back longitudinal slot until spring-loaded locking eccentric locks into spring clip position with elevation.
  • On CL55, CL500, CL600, S55, S430, S500 and S600 models...

CLICK HERE TO GET FULL ACCESS TO 2002 MERCEDES-BENZ ML500 BRAKE SERVICE PROCEDURES

BRAKE SERVICE PROCEDURES FOR 2002 MERCEDES-BENZ ML500 AUTOMOBILES

Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported 2002 MERCEDES-BENZ ML500 cars and light trucks from 1990+.

Power Brake Units -> Diagnosis & Testing -> Brake Booster -> Non-Return Valve
Vehicle: 2002 MERCEDES-BENZ ML500 5.0 V8 GAS

Non-Return Valve

  • Disconnect brake booster vacuum line.
  • Connect pressure tester tool No. 201 589 13 21 00, or equivalent, between brake booster and vacuum line.
  • Start engine and create 10.9-11.6 psi vacuum by opening and suddenly releasing throttle.
  • Turn engine off.
  • If vacuum drops more than 2.9 psi in 30 seconds, replace vacuum line.
  • Torque vacuum line to 22 ft. lbs.

Brake Booster

  • Disconnect brake booster vacuum line.
  • Connect pressure tester tool No. 201 589 13 21 00, or equivalent, between brake booster and vacuum line.
  • Connect suitable pressure tester at brake caliper.
  • Connect Bosch ...

CLICK HERE TO GET FULL ACCESS TO 2002 MERCEDES-BENZ ML500 BRAKE SERVICE PROCEDURES

BRAKE SERVICE PROCEDURES FOR 2002 MERCEDES-BENZ ML500 AUTOMOBILES

Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported 2002 MERCEDES-BENZ ML500 cars and light trucks from 1990+.

Disc Brakes -> Adjustments -> Parking Brake
Vehicle: 2002 MERCEDES-BENZ ML500 5.0 V8 GAS

Parking Brake

  • Raise and support vehicle rear.
  • On SL55, SL500, SL600, SLK32, SLK230 and SLK320 models, loosen adjusting bolt.
  • On all models, remove one wheel bolt on both rear wheels. Light alloy wheels must be removed.
  • Turn adjuster until brake shoes contact and it is no longer possible to turn rear wheel, noting the following:
    • Use suitable .1772 inc...

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