M-Class (W163) Produced 1998-2005: ML 230, ML 320, ML 350, ML 400 CDI, ML 430, ML 500, ML 270 CDI

Torsion Bar reassembly

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Old 04-21-2016, 10:28 AM
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1999 ML 320
Question Please, Please HELP with torsion bar reassembly

Hello everyone.
Please help me with a problem re installing the torsion bar on my 1999 ML320 (W163). After I removed the long bolt in the rear of the torsion bar ( so I can get clearance to my catalytic converters ) I am trying to re install it, but the screw is nowhere near the bracket on the torsion bar. How can I twist the torsion bar so the thread on the bracket/arm attached to the torsion bar will align with the hole on the plate though which I have to insert the long screw?
Attached Thumbnails Torsion Bar reassembly-20160421_165244.jpg   Torsion Bar reassembly-20160421_165255.jpg  

Last edited by KingFloyd; 04-22-2016 at 02:24 AM. Reason: Forgot something
Old 04-22-2016, 07:17 AM
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2002 ML 320 & 2006 ML500
Recheck the procedure.
Attached Files
File Type: pdf
R&I Torsion Bar #1.pdf (92.5 KB, 387 views)
File Type: pdf
R&I Torsion Bar #2.pdf (144.2 KB, 305 views)
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Old 04-22-2016, 04:20 PM
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Thank you . I will try it again, but as I said, that screw (16c) does not reach the nut on the clamping lever (16d) with the counterplate (16b) in place. How can I manipulate the torsion bar so the clamping lever twists (aligns itself) closer to the hole so the bolt can reach the nut on the clamping lever. My clamping lever is all the way up pressing against the floor of the car (see pic 1)....
Once again thank you for sharing the procedure an I will try it again

Last edited by KingFloyd; 04-22-2016 at 04:28 PM. Reason: misspelling
Old 04-23-2016, 06:08 AM
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Maybe you should use the other torsion bar as a guide.

You were suppose to mark everything after you initially raised the front wheels off the ground.
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Old 04-23-2016, 03:24 PM
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Thank you all for your help. I was able to align the torsion bar wit the counter plate and get the bolt through. I was raising the wheels off the ground one side at a time, instead of both at the same time, which is imperitive in this operation. If you don't raise both sides simultenously, it won't release the pressure off the tosion bar.
Thanks again Maj Dundee. Something so obvious can be sometimes overlooked. Thank you.
Old 08-31-2019, 01:18 PM
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I just did this on my ML320. I learned that the nut that the long screw goes into "moves". It is on top of the rectangular box and it "rotates a little" and there is enough room on top of the box to get a finger in there. If you put your index finger on the nut you can alter its direction enough to have it line up with the direction of the screw and get the first threads started. For me, the hardest part was starting the threads on the long bolt.
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