I don't have any tips for brake line replacement but you should absolutely not drive the ML with no hydraulic brakes. Rent an auto-transport from UHaul, if you don't have a vehicle that can tow rent a truck too. Cheaper than a new car.

 

there's brake line repair kits on ebay I see ,so I guess decent auto parts places may have these... I guess you may need a flaring tool as well...

 

I found these as a kit Brake line kit

Another one with with the flare tool

I read that MB lines end with a bubble. But, if we are cutting and replacing a section, flare should do it, right?

 

I found these as a kit Brake line kit

with the flare tool

Unless you have experience with flaring tools stick with premade brake lines.

4.75mm Brake Line Ends M10X1.0 Ends Bubble Flare Preassembled Tubing

Bel-Metric sells metric hardware & specialty automotive supplies worldwide. Visit our website to purchase metric fasteners, nuts, bolts, screws, washers & more.

belmetric.com

FG 163.157 - BRAKES > Mercedes EPC Online > nemigaparts.com

Parts catalogs. Spare parts catalog Mercedes EPC Online. Mercedes. Car. BRAKES.

nemigaparts.com

 

The way W163 was built everything got assembled to the frame then body shell was lowered and bolted to it.
I think it would be easier to replace those lines in sections and join them with union.
Maybe @Noodles has some tips. He deals with rusty cars.

M10X1.0 Brake Union Double + Bubble Flare 4.75mm or 3/16" Line

Bel-Metric sells metric hardware & specialty automotive supplies worldwide. Visit our website to purchase metric fasteners, nuts, bolts, screws, washers & more.

belmetric.com

 

Found the leak. Driver side inside the wheel. Lower one shoots up the fluid right where the clamp is.

 

Had I known you are shopping for another W163 I would gift you my '99 ML320.

 

Witek, replacing the whole line is going to be a nightmare. I may break more lines while wiggling other lines. I can't even tell the ruptured lower line it the rear right or left rear wheel.

I bought 2 compression fittings, line, line cutter and flare tool from Autozone. I can give it a try to patch this but condition of the line is nightmare. I need to watch a lot of videos about how to do this right.

 

Witek, replacing the whole line is going to be a nightmare. I may break more lines while wiggling other lines. I can't even tell the ruptured lower line it the rear right or left rear wheel.

I bought 2 compression fittings, line, line cutter and flare tool from Autozone. I can give it a try to patch this but condition of the line is nightmare. I need to watch a lot of videos about how to do this right.

Do not use compression fittings on brake lines.

 

Oreilly and the others sell the AGS brand line sections and the unions.
I use the copper nickel alloy due to its ease of bending and excellent
corrosion resistance. I have what's left of a 50ft roll and unions because
I know I am going to need it.

 

It's been a hell of an experience to learn a) how to use the double flare tool and b) buy the correct parts. AGS brand brake line (part number: PA-320), 2x union nuts, and 2x fittings, (all 3/16 size and standard=inverted=double flare). You can not mix the US, Japanese, and European parts together. These are labeled PA-xxx, PAJ-xxx, and PAE-xx, respectively. It's easy to get confused when shopping at the auto store. Flushed the brakes and no leak after the test drive.

 

Doing the double flare on steel lines can be tricky. I used to have to do them on the trailers we use to make. If I remember correctly the kit for the double flare back then was about $350. I still have it today though it’s a great kit and I still use it on the old cars I restore.


Sent from my iPhone using Tapatalk

 

The better tool makes the flaring easier and more consistent.
The $30 tools are junk and just waste peoples time. That is one
tool worth spending good money on.

 

Did you end up replacing just the bad spots or closer to 95% of the lines?

 

I only replaced 20" in the engine compartment. The rear sections were replaced before.

 

First one was the ML430 about 12 years ago and I got the entire line kit from MB.
It was still a bear to do. So much so that when the 2000 ML320 needed line repair
I just bought all the good bulk stuff and did all of the lines that showed any corrosion.

 

So I too had to recently replace the brake lines for the rear brakes. The 2 brake lines to the reservoir are also rusting right by the bend before the pump. I don't understand how this portion is rusted. In any case none of the dealers in my area has this brake line and all places online do not have it. A few places say it's no longer manufactured. The part numbers are:

163-420-64-26-64
163-420-65-26-64

Can these lines be custom made or does it have to be factory made?

 

So I too had to recently replace the brake lines for the rear brakes. The 2 brake lines to the reservoir are also rusting right by the bend before the pump. I don't understand how this portion is rusted. In any case none of the dealers in my area has this brake line and all places oine do not have it. A few places say it's no longer manufacturered. The part numbers are:

163-420-64-26-64
163-420-65-26-64

Can these lines be custom made or does it have to be factory made?

It looks like MBOemparts.com have these. You can search other online shops too.
Brake Line - Mercedes-Benz (163-420-64-26-64)

• MSRP:$90.00
• Discount:$23.31 (25.9% off)
• Sale Price:$66.69

Line - Mercedes-Benz (163-420-65-26-64)

• MSRP:$94.00
• Discount:$24.44 (26% off)
• Sale Price:$69.56

I bet these lines will NOT be shipped pre-shaped. But at least they will be just the right size and come with correct fittings.

 

It looks like MBOemparts.com have these. You can search other online shops too.
Brake Line - Mercedes-Benz (163-420-64-26-64)

• MSRP:$90.00
• Discount:$23.31 (25.9% off)
• Sale Price:$66.69

Line - Mercedes-Benz (163-420-65-26-64)

• MSRP:$94.00
• Discount:$24.44 (26% off)
• Sale Price:$69.56

I bet these lines will NOT be shipped pre-shaped. But at least they will be just the right size and come with correct fittings.

I'll try from MBOemparts.com but the other sites that I have tried canceled my order and refunded my money stating that the part is no longer available.

 

Some retro reading for you:

ML 500 Brake Line Replacement

I am looking to replace all of my brake lines. Mechanic suggested to replace as they are rusted and there is air in the system. I matched it up and they seem to be 3/16” what size do you guys use and how much is necessary I got 25 feet of 3/16” in copper. Also what is recommended brake fluid? I...

www.benzworld.org

 

Somewhere in Europe:

https://allegro.pl/uzytkownik/PHU_DONOCIK/uklad-hamulcowy-przewody-hamulcowe-250429

Switch to English by hitting white/red round button on top.

 

I like the AGS copper nickel line. It is easy to bend and flare
or make a bubble and very corrosion resistant.

 

So I've tried again to get the MB made brake lines and no MB dealer has it and every one I've contacted said its no longer made. Aside from making my own lines out of copper nickel, can I use a new brake line from another MB? Meaning maybe a 2006 ML (or maybe older/newer) or one from an E class? Does anyone know if the factory brake line diameter of another MB and fittings are the same as the W163 and can be bent to the W163 shape?

 

DarkManX4if,

FYI

I have replaced both master cylinder to ABS brake inlet lines on a 2004 ML, both lines were
6mm (1/4" brake line will work, original lines O.D. measured .2380" and .2371") bubble flares
on both ends of each.

When you use 1/4" SAE Brake tubing, you have to run a 1/4" drill bit through the old metric fittings
if reusing them, as the SAE line O.D.is slightly larger.

You should check the O.D. before ordering bulk tubing and fittings.

 

Here is good source for metric brake line stuff.

Fittings - Brake Lines + Fittings - BelMetric

belmetric.com

 

I use them to keep my box of fittings full.
The crap I have tried on Amazon is inferior compared to their fittings.