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Home >> Mercedes Benz >> 2002 >> ML55 >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> Disc Brakes - 163 Chassis (Except Ml430) >> Removal & Installation >> Brake Booster >> Removal & Installation

Removal & Installation

  1. Remove brake master cylinder. See BRAKE MASTER CYLINDER  .
  2. Remove position sensor bracket nuts (4) on splash wall. Pull out hoses (21) from bracket and unclip bracket from splash wall. Remove connector and swing to one side. See Fig 1 .
  3. Disconnect Brake Assist System (BAS) diaphragm travel sensor harness connector (A7/7b1).
    4. NOTE: Risk of plastic locking clips (20) cracking and fracturing.
  4. Remove plastic locking nut (19) on splash wall.
  5. Disconnect harness connector of release switch (27).
  6. Remove cover below instrument panel. See COVER BELOW INSTRUMENT PANEL  .
  7. Remove brake pedal retainer (25) and bolt (26).
  8. Remove brake booster nut (23).
    9. NOTE: When removing brake booster from pedal bearing bracket (22), DO NOT damage timing case.
  9. Remove brake booster (16) through engine compartment.
  10. Installation is the reverse of removal. Replace gasket (16d). Adjust brakelight switch (S9) by removing and installing. See BRAKELIGHT SWITCH  . Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS  . Bleed brake system. See BLEEDING BRAKE SYSTEM  .
Fig 1: Removing & Installing Brake Booster
G00321185Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
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