2000-2006 Mercedes-Benz S500 4 Wheel Conversion Kit Installation Manual - Strutmasters
2000-2006 Mercedes-Benz S500 4 Wheel Conversion Kit Installation Manual
Take a look at our easy-to-follow 2000-2006 Mercedes-Benz S500 4 Wheel Conversion Kit Installation Manual to learn how to install your new Strutmasters air suspension conversion kit. Our step-by-step instructions include pictures to help you along the way.
Mercedes-Benz S500 parts included in this kit:
- 4 Coilover Strut Assemblies
- 4 Hydraulic Line Plugs
- Read general service precautions
- Wear Eye Protection
- Support the vehicle
- Remove air suspension parts
- Install conversion kit
- Disable the ride control light
Tools needed for installation:
- Metric socket set
- Floor Jack
- Jack Stands
- Metric Wrench Set
- Wire Cutter/Stripper/Crimping Tool
- Level Work Surface
- Spring Compressor (If Applicable)
- Metric Allen Wrenches
- Torx Bits
- Screw Drivers (Phillips and Flat-Head)
- Air Impact
- Pry Bar
- Vise and or Vise Grips
- Mercedes-approved Hydraulic Steering Fluid
Front ABC Strut Removal InstructionsStep 1
Caution: A sudden release of pressure may cause personal injury or damage to the vehicle. The air suspension system is under pressure until the air supply lines are disconnected. Use the following precautions when servicing the air suspension system: Wear gloves, ear protection, and eye protection. Wrap a clean cloth around the air supply lines. The vehicle must be raised to perform this conversion! Use proper lifting equipment only! Read instructions carefully before attempting installation, if you have problems during the install then feel free to call our Technical Support Line. Please before calling for technical help, have your invoice handy.
Before lifting vehicle:
- Look behind the rear headrests in the corners at what looks like speaker covers. This is the access cover to the OEM struts mounting studs and electrical connector. Carefully remove this cover and sound insulation.
- Remove the electrical connectors by pinching tabs and pulling up.
- Remove the three 13 mm retaining nuts from the studs.
- Now, open hood and locate struts electrical connector and remove from struts, see Fig 2.
- Remove the three 13 mm retaining nuts from the top of the strut.
Notice: THE MERCEDES SUSPENSION SYSTEMS FOR THE “S” CLASS VEHICLES WERE DESIGNED WITH THE FACTORY TIRES INSTALLED. TIRE SIZES INCLUDE: 225/55R17, 245/45R18, 265/40R/18, 275/40R18, 245/40R19, 275/35R19.
SHOULD YOUR VEHICLE NOT HAVE ONE OF THESE FACTORY TIRE SIZES INSTALLED, THEN YOU WILL EXPERIENCE VARIOUS DIFFERENCES IN THIS KITS PERFORMANCE. THERE IS LIMITED TECH SUPPORT FOR VEHICLES USING ANYTHING OTHER THAN ORIGINAL TIRES. PHOTOS WILL BE REQUIRED FOR TECH SUPPORT.
- Raise vehicle and remove tire.
- Locate the hydraulic line coming from the strut down to the quick disconnect. Follow the steel line to the bleeder valve, see Fig 2.
- Make sure your eye protection is on. Using a 10 mm wrench, open the bleeder valve to drain off fluid pressure. Strut may retract enough to remove itself from the upper mounting holes.
- Disconnect the hydraulic line from the frame. Then separate the rubber line from the metal line at the quick disconnect, see Fig 3.
- Remove the two lower set screws. With a 5.5 mm allen wrench or socket, see Fig 4.
- Remove strut from vehicle you may need to pry control arm down to remove strut from pin.
- Before installing the new conversion strut you need to remove the hydraulic line from the factory strut, see Fig 5 & Fig 6.
- Install the supplied brass cap on the threaded end of the hose, see Fig 7.
- Make sure cap is tightened enough so that the fitting will not turn, see Fig 8.
- Install the line back in to the quick disconnect on the car. Bolt line back to frame.
Rear ABC Strut Removal InstructionsStep 2
- Ensure caps at the top of the struts are disconnected, see Fig 1.
- Place a jack under the control arm to support it, see Fig 2.
- Follow the hydraulic line from the strut to the bleeder valve. Open valve with 10 mm wrench to drain fluid (wear eye protection).
- Using a 21mm socket and wrench remove the struts lower mounting nut from the bolt. (Leave bolt in place), see Fig 3.
- Using a 13 mm wrench remove the height sensor arm from the control arm. This must be done to prevent breakage, see Fig 4.
- Using an 18 mm wrench loosen the inner control arm nuts. (LOOSEN ONLY), see Fig 5.
- A 12mm Torx bit and 18mm wrench is needed to remove the track bar from the hub, see Fig 6.
- Use a 21mm wrench and 9/16 box-end wrench to remove the hub to lower control arm bolt, see Fig 7. CAUTION: Control arm may drop down.
- )If control arm did not drop, pull hub slightly out and upward. Lower control arm should drop down along with strut, see Fig 8.
- 13) After control arm has dropped you should have access to the quick disconnect on the side of the strut. Disconnect line and then remove the lower bolt holding the strut, see Fig 9.
- Remove strut from vehicle.
- Before you can install the new strut you will need to remove the steel line from the original strut, see Fig 10 & Fig 11.
- Cap the threaded end of the line with the supplied brass cap TIGHT, see Fig 12.
- Install steel line back into the quick disconnect on the car and tuck the line in behind the wheel liner. Fig 13
- Repeat steps for opposite side removal.
Front Conversion Kit Installation InstructionsStep 3
- Remove the upper three nuts and washers from the strut.
- To install the new strut into position align the studs to fit into the stud holes in the fender. Then push up so the studs protrude through the holes. Install the new washers and nuts loosely at this time, see Fig 1 & Fig 2.
- Pull the lower control arm down using a pry bar and guide the bottom of the strut over the control arm pin, see Fig 3.
- Release the control arm so that the pin raises into the struts lower mounting hole; arm may need to be raised to fully seat pin.
- Make sure the pin is fully seated up into the strut Then tighten the set screws, see Fig 4. Failure to fully seat the pin or tighten the set screws will result in damage to either the strut and or the pin and is not covered under the warranty.
- Tighten the three stud nuts on top of the strut.
- Make sure the hydraulic line is secured away from moving suspension components.
- Make sure all nuts, bolts and screws are tight.
- Install wheel and torque lugs to factory specs. Fig 5
- Repeat steps on opposite side of vehicle.
Front Conversion Kit installation now complete.
Rear Conversion Kit Installation InstructionsStep 4
- Two people will be required to install the rear strut.
- Remove the nuts and washers from the top of the new strut.
- Look at the stud pattern on the strut top, then look up into the strut tunnel on the car to see the hole pattern at the top. Align the strut to fit the pattern.
- Raise strut up into tunnel and work the strut into the stud holes until the studs protrude through the holes, see Fig 1.
- Have the other person install the washers and nuts on the studs and tighten (You can let the strut hang in place).
- Raise the lower control arm up until you can align the struts lower bolt hole, install bolt and nut and tighten, see Fig 2.
- Place hub back into the control arm and install bolt and nut and tighten, see Fig 2 & Fig 3.
- Install the track bar back to the hub and tighten bolt, see Fig 4.
- Tighten the inner control arm bolts, see Fig 5.
- Reconnect the height sensor, see Fig 6.
- Make sure all bolts are tight.
- Install the rear strut top cover in the rear window.
- Install wheel, and torque lugs to factory specs.
- Make sure fluid level is correct in the hydraulic fluid reservoir, see Fig 6 & Fig 7.
Conversion Kit installation now complete.