The ML is tricky but not as difficult to maintain and I have a cls55 AMG so I'm familiar with high costs. I like brute force so I have the ML55 and it's a monster. The ML500 is a nice choice and the engine seems to enjoy the work as opposed to the 320 which sometimes feels like it's struggling a bit. All in all the ML is a truck not a car so it will ride a bit stiffer. As for the W164 I can't help you with that. One more point bears mentioning. They rust. Yep just like your daddy's 1968 Chevy did. For some reason they rust and despite best efforts the rust is a chronic problem. I stay on mine so it looks pretty good but I expect to replace some major frame components in the near future. Good luck.
Actually, so far I have only been able to test drive two. One was totally messed up, but the ride was more supple than with me e320 with 16" wheels.
The other, a one-owner car, a 2004, had such a stiff suspension - no idea how they got it that way - maybe by not maintaining it at all?
I'm in California and only look for cars that have been driven here all their lives - not hard to find here. So rust is not an issue.
What I like about the older models is that their engine/transmission combinations are really hard to kill.
So far couldn't get a hold of an ML500 163. They are older now, and had sometimes 5 or 6 owners... too many, and the last two only keeping the car for two years... bad signs.
Still looking for the well maintained one with patience.
Definitely look at the later years of the W163 and in the V8 model. They will all be pretty harsh in the ride in comparison to your E class. I think when you buy cars as old as ours maintenance will be a lucky dip. Just hope the one you find has been well looked after.
I have an 01E430 and a 05 ML500. I traded a 02 320 for the 500, both over 100K miles, and have and are still serving me quite satisfactorily. All purchased new. The 320 was the most problematic. The 430 almost mirrors the 500 with respect to repairs - very similar electronic, transmission and motor related issues in my case. As a result, the repair cost is very close with both being expensive, on average, compared with my Nissan. In general though, post warranty, the E has held better than the ML in terms of repairs, and I drive the E more. Some of my ML issues I don't have with the E are failing torsion bar bushings ($$), leaky trans line at radiator fitting ($$), failed drive shaft center bearing ($$$), failed ball joints ($$$$), failed tie rods ($$$$) and failed fuel pump ($$$). I did replace the ball joints on the E but that was just due to age. The ML500 also has a noisy brake issue which MB had since resolved - but a costly fix compared with the E. Brake job on the 500, in general, are more costly than on the E's. I wouldn't expect that with the 320 though. Lucky for me, rust has not been a major issue - both have some small rust spots which probably will cost same to fix.
One thing for sure is that in their old age, they seem to be satisfyingly way less problematic:smile
Others have reported harmonic balancer issues on the ML - can be very costly depending on when it happens and what it takes with it. There are also reports of rusted out fuel lines on the rear drivers side of the ML which can be quite costly. Some have also reported unexpected brake locking on the MLs - I have not had that issue on either vehicle, but I can imagine it being a costly problem.
For W164 issues, you may want to ask the 164 folks. I have driven quite a bit of 164 MLs and I like the drive. I just don't care for the design.
Could it be that those earlier repairs were fixes of design flaws - which is why they performed better in their mature age?
Gladly I have a very good mechanic who will check the car before I'm buying.
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