Description
Factory Mercedes ML500 4Matic Workshop Manual (2006-2007)
This official workshop manual delivers factory-level service and repair coverage for the W164-generation Mercedes ML500 4Matic – the full-size luxury SUV that dominated American roads in the mid-2000s. Built for technicians and serious DIYers alike, it provides the depth needed for everything from routine maintenance to complex drivetrain work.
Powertrain & Drive Coverage
| Component | Variants Covered |
|---|---|
| Petrol | M113 5.0L V8 (288 hp), M273 5.5L V8 (382 hp) |
| Diesel | N/A |
| Transmissions | 722.6 5-speed automatic, 722.9 7G-Tronic 7-speed automatic |
| Drive | 4Matic permanent AWD |
| Model Years | 2006-2007 |
| Badge Twins | N/A |
Common ML500 Repairs Covered
| System | Procedures |
|---|---|
| Air Suspension / ABC | Airmatic strut replacement, ride-height sensor calibration, compressor service |
| 4Matic Transfer Case | Transfer case fluid service, front differential seal replacement, driveshaft R&R |
| Engine Cooling | Plastic coolant fitting and expansion tank replacement (known failure point on M113/M273) |
| Brake System | Front and rear pad/rotor replacement, ESP/ABS module diagnostics, brake fluid flush |
Format & Delivery
PDF. Instant download; lifetime re-downloads.
Frequently Asked Questions
Why do plastic coolant fittings fail on the ML500, and does the manual cover the fix?
The M113 and M273 V8 engines used in the ML500 rely on several plastic coolant distribution fittings and an expansion tank that become brittle with age and heat cycling. This is a well-documented failure mode that can lead to sudden coolant loss. The manual covers the full cooling system, including component locations, draining procedures, torque specs for replacement hardware, and coolant capacity/flush intervals.
Which chassis generation does this manual cover – W163 or W164?
The 2006-2007 date range falls on the W164 platform, which was introduced for the 2006 model year. The W163 (1998-2005) is a separate generation and is not covered by this manual. If you own a pre-2006 ML500, you will need the W163-specific publication.
Are the 4Matic AWD system and transfer case procedures included?
Yes. The manual includes dedicated coverage of the 4Matic permanent all-wheel-drive system, including the transfer case, front and rear differentials, prop shafts, and the associated control modules. Fluid specifications, torque values, and removal/installation sequences are all documented.
What format is the manual?
The manual is delivered as a PDF file. After purchase you receive an instant download link, and the file can be accessed on any Windows or Mac computer, tablet, or smartphone with a PDF reader. Pages can be printed individually or in sections for bench use.
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