This hasn't happened since I stopped using steroids.

 

Good one!

 

I guess I don't know my own strength.

In all honesty, I didn't pull hard. This is my eight vehicle in 22 years and the first time this has ever happened.

 

Re: Handle for Emergency Brake came off

Hi,

This same thing happened to my wife a while ago on her '08 ML350.
I believe her that she didn't pull it that hard either
but even if she did a bit, it should not break like that.

We took it to the dealer and they covered it under Warranty.
They admitted an internal component had failed.

You know, sometimes a person can think the emerg brake is engaged when
really it is not and then they keep pulling it harder and harder
and nothing happens which could end up forcing this part to break.

 

Emergency Brake Handle Came Off

Exactly the same thing happened to our '07 ML350. My 120lb wife pulled the handle right off. I had some success repairing it and since I always find useful information on this forum, I thought I'd share what I found.

Firstly there is a major design flaw with the handle guide part of the 2 part mechanism. The counterbore that holds the cable jacket in place and offer resistance when the cable is pulled is too deep and the thickness of the remaining plastic is too thin to withstand the pulling forces. I am not surprised that slight women can break these easily (not a good situation when you consider that there car is not going anywhere until someone technical can release the brake).

Second point, I could not find the spare part anywhere on the internet. Of the 5 part numbers on the 2 parts, only one came up on a Google search (in Romania!). As a result I took it upon myself to repair it as follows:

Remove the 2 torx screws and gently leaver the handle guide away from the dash by the top edge. With a 6-8mm drill bit make a new slightly larger, but shallower than the original, counterbore that fits a metal washer you have on hand. The washer's inner diameter must be less than the cable jacket outer diameter. Then cut a slot out of the washer big enough for the the cable to slot through. Glue the washer into the counterbore with a 2 part epoxy. Slot must face upwards to accept the cable. Allow epoxy to set overnight.

Fitting the handle back was quite difficult. Access is through the dash side panel which can be gently prised off. Unlike my CLK350, where there is a fuse box here that can be removed, the ML has a tiny space and you'd need very small hands to work in this space. I found it easier to removed the 3 torx screws underneath the dash and get my hand round the back. To further spread the load I added another washer, split open and then crimped closed over the cable. With the both parts of the brake release mechanism installed in the dash, fit the ball-end of the cable and pull the cable jacket back to fit in the new reinforced counterbore you have made. The result should be much stronger than the original, though time will tell. Right now I feel more confident in this repair than I would in a brand new OEM part.

Sorry I have no pictures, but hopefully this helps someone.

 

Emergency Brake Release Handle Repair

The handle came loose on my 2007 ML350 this week at 62000 miles. I have had no repairs up until now except wiper blades, bulbs and tires. I tried this repair method and it was quite successful. I have nothing to add except a few pictures and another idea for fitting the cable back in position.
This is what it looks like with the handle and the guide removed.

This is the handle inside the guide. You can see the slot where the cable goes. The cable jacket comes in from the left and should be stopped in the plastic counterbore.

This is a closeup of the washer I have epoxyed into the 5/16 (about 8mm)hole I drilled per the instructions.

The assembly looks like this when finished. Unfortunately you can't attach it back in place like this. The handle has to be out of the way to attach the guide back in place.

After the handle and guide are back in place you can access the area behind by removing the panel on the side. Notice the are 3 clips that can be pried loose. The forward edge of the panel can be worked out from under the weatherstrip and removed completely.

I was able to fit the cable back in place through this side opening by maneuvering it with a long hemostat and screw driver.
It's only been a few days since the repair but it's working just fine. I do think the part has been changed. In researching (Google) the part number on the guide, A2514200077, I found a website (non-US dealer, I think) with a notation saying not to use this part but to use A2514200177 instead.
Hope all this helps.

 

Emergency Brake Release Handle Repair

The handle came loose on my 2007 ML350 this week at 62000 miles. I have had no repairs up until now except wiper blades, bulbs and tires. I tried this repair method and it was quite successful. I have nothing to add except a few pictures and another idea for fitting the cable back in position.
This is what it looks like with the handle and the guide removed.
View attachment 421416

This is the handle inside the guide. You can see the slot where the cable goes. The cable jacket comes in from the left and should be stopped in the plastic counterbore.
View attachment 421417

This is a closeup of the washer I have epoxyed into the 5/16 (about 8mm)hole I drilled per the instructions.
View attachment 421418

The assembly looks like this when finished. Unfortunately you can't attach it back in place like this. The handle has to be out of the way to attach the guide back in place.
View attachment 421422

After the handle and guide are back in place you can access the area behind by removing the panel on the side. Notice the are 3 clips that can be pried loose. The forward edge of the panel can be worked out from under the weatherstrip and removed completely.
View attachment 421419

I was able to fit the cable back in place through this side opening by maneuvering it with a long hemostat and screw driver.
It's only been a few days since the repair but it's working just fine. I do think the part has been changed. In researching (Google) the part number on the guide, A2514200077, I found a website (non-US dealer, I think) with a notation saying not to use this part but to use A2514200177 instead.
Hope all this helps.

The part number for the release CABLE only is A1644200185. This fits the W164 and the W251. It's a hard find without the part number on ebay. This is the cable that connects the pull handle to the foot brake to release the park brake.

 

Good info Jeremy B and BillM. Thank you for posting these detailed remedies. Hopefully this doesn't happen again, but who knows. Dealer fixed under warranty.

 

Yes, happened to me also. Fortunately under warranty.

Jim W.

 

Another fix!

Got an alternate way to repair! Easy, permanent, strong.

Bend a 1/2" u-shaped bracket to place over the counterbore. Drill a 1/4" hole at one end to allow the cable end to pass through the bracket. Cut a slot in the other end of the bracket to allow the cable to pass through.

Re-install by running the cable end through the bracket, place the bracket over the counterbore, pull the cable end through the slotted end of the bracket, and attach cable end to handle guide.

Re-mount the handle with the two screws.

Done!

 

Another fix! Bracket

Better shot of the bracket!

 

I like the idea. Would some small grommets in the drilled hole/slot make sense to protect the cable?

 

An update on the repair I posted on 1/19/12: After about 18 months the brake release handle started to "hang-up". The cable had begun to fray where it passes through the metal washer. As the strands broke they prevented the handle from retracting all the way. Eventually it stuck in the out position. I took it all apart and decided to let the dealer repair it with what I assume are updated parts.

 

Grommets would be a great improvement! Will take care of the potential wear out issue.

 

Very helpful. I went one step further, I taped on top of of the ball, with aluminum tape, so that it does not pop out.

Scary experience, poor design MB.

 

Found the part on EBAY

Hi all,

I have the same problem on my 06 ML320CDI. I park on a steep drive so the part is often used. My wife too ripped it out and until I saw this thread, I thought she must have been too agressive with it but it looks like it simply gives way with use.

A quick search and I found the part number:

For those who would rather just replace the whole handle guide (the chassis the actual handle slides in) following those great photos and advice above then go order it. Its part #A2514200177 .

I found it from Ebay UK for about $35 delivered. Just search for "A2514200177"

The actual handle which attaches to the cable and slides in the handle guide is part #A2514200077 ....just in case you need that part as well for some reason.

Good Luck all. As these cars get older, this is likely to brake more often.

 

Found the part on EBAY

Hi all,

I have the same problem on my 06 ML320CDI. I park on a steep drive so the part is often used. My wife too ripped it out and until I saw this thread, I thought she must have been too agressive with it but it looks like it simply gives way with use.

A quick search and I found the part number:

For those who would rather just replace the whole handle guide (the chassis the actual handle slides in) following those great photos and advice above then go order it. Its part #A2514200177 .

I found it from Ebay UK for about $35 delivered. Just search for "A2514200177"

The actual handle which attaches to the cable and slides in the handle guide is part #A2514200077 ....just in case you need that part as well for some reason.

Good Luck all. As these cars get older, this is likely to brake more often.

The part number for the release CABLE only is A1644200185. This fits the W164 and the W251. It's a hard find without the part number on ebay. This is the cable that connects the pull handle to the foot brake to release the park brake.

 

Man, MB is making some cheap shit, and it's really starting to piss me off!!!

 

You do realize that this thread was started 9 years ago, right? Good for future searchers though.

Just letting you know you probably won't get a reply. And welcome to BenzWorld, we need a "Real Mr. Fixit"!

 

Sept 2024 and my x164 2007 model handle did the same Thank you guys for the info. It shows that old info stays relavant