2006 Dodge Sprinter 3500

From 2000 through 2017, Takata produced millions of air bag inflators using two types of phase-stabilized ammonium nitrate ("PSAN") propellant -- propellant 2004 and propellant 2004L. After prolonged exposure to high temperature cycles and humidity, inflators using propellant 2004 can degrade, causing the propellant to burn too quickly when ignited. The rapid burning can cause the inflator to rupture during deployment, potentially causing serious or even fatal injury to vehicle occupants. See 2016 Blomquist Report at www.nhtsa.gov/sites/nhtsa.gov/files/documents/expert_report-hrblomquist.pdf.Consequently, all frontal inflators using propellant 2004 that do not contain a "desiccant" (a substance that traps and holds moisture) in US vehicles are under recall. These "non-desiccated" inflators either have been or are required to be replaced.In some cases, the remedy part for these recalled inflators was, or will be, an inflator using either propellant 2004 or 2004L that does contain a desiccant. None of these "desiccated" remedy parts (which were installed in older model year vehicles) are currently under recall for a degradation concern. Certain subsets of desiccated PSAN inflators using propellant 2004 for use as original equipment, however, have been recalled for a degradation concern. All Takata inflators produced with propellant 2004L contain desiccant, and none of these desiccated inflators using propellant 2004L are under recall for a degradation concern. There have been no reported field ruptures in any non-recalled desiccated PSAN inflators.It is understood that desiccants fully saturate at some threshold, at which point any additional moisture will not be captured. This means the degradation process observed in non-desiccated inflators using propellant 2004 may also occur in non-recalled desiccated inflators using propellant 2004, assuming additional moisture enters the inflator and high temperature cycling occurs. Based on available information, desiccant saturation can occur within the first five years in the worst environments, and the time required for full saturation is affected by multiple factors. While no present safety risk has been identified, further work is needed to evaluate the future risk of non-recalled desiccated inflators using propellant 2004.Three entities -- Takata (now known as TK Global), the Independent Testing Coalition, and Exponent -- have been studying the long-term behavior of Takata desiccated PSAN inflators using propellant 2004L (as well as 2004) in the presence of moisture and temperature cycling. The research efforts, which include development of predictive modeling techniques and field sample analysis, are ongoing. To date, none of the researchers have identified field evidence showing that propellant 2004L is undergoing a degradation process that leads to aggressive deployment and potential rupture. However, the time in service of such inflators remains short compared to that of the inflators using propellant 2004. Further study is needed to assess the long-term safety of desiccated inflators using propellant 2004L.The Office of Defects Investigation is opening this investigation to examine whether a safety defect related to propellant degradation exists in non-recalled desiccated PSAN frontal inflators manufactured by Takata. This investigation will require extensive information on Takata production processes and surveys of inflators in the field. Lists of recall actions that may have used desiccated PSAN inflators as remedy parts, as well as the makes and models originally manufactured with them, is available with the downloadable version of this document (see nhtsa.gov/recalls?nhtsaId=EA21002 -- note this information is subject to change/revision as the investigation proceeds). This investigation does not supersede EA15-001, which remains open.

The contact owns a 2006. Dodge Sprinter 3500. The contact received notification of NHTSA Campaign Number: 16V833000 (Electrical System, Service Brakes, Hydraulic), and Emissions Recall T21 Reprogram Engine Control Unit however, the parts to do the recall repairs were not yet available. The local dealer was contacted. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repairs. The manufacturer was made aware of the issue. The contact had not experienced a failure. Parts distribution disconnect.

NHTSA ID

11579710

Incident

Mar 27, 2024

2006 DODGE SPRINTER 3500. CONSUMER WRITES IN REGARD TO EGR VALVE FAILURE. THE CONSUMER STATED THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME COMPLETING THE RECALL REPAIR. THE PARTS WERE UNAVAILABLE.

NHTSA ID

11484577

Incident

Sep 15, 2022

The contact owns a 2006 Dodge Sprinter 3500. The contact received a recall notification for NHTSA Campaign Number: 16V833000 (Electrical System, Service Brakes, Hydraulic) and for an unknown Manufacturer recall for the engine control unit failure however, the dealer informed the contact that the parts for the recall repairs were not yet available. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was notified of the issue and advised the contact that they would assist with locating a dealer who could complete the recall repairs. A case was opened. The contact was awaiting a call back from the manufacturer. The contact had not experienced a failure. Parts distribution disconnect. Consumer stated the recall items were issued sometime early on (2006) and the timeline for repairing the recall items is 2006-Dec 2021. 12 dealers were contacted and none could work on it and consumer still has two recall items pending.

NHTSA ID

11437315

Incident

Oct 19, 2021

I HAVE TWO RECALLS THAT NEEDS TO BE DONE BY A DODGE DEALER WHICH I TRIED TWO YEARS AGO WITH NO SUCCESS, THE FIRST ONE IS BRAKE LIGHT RECALL NONE OF THE DODGE DEALERS IN MY AREA UP TO 50 MILES RADIUS WERE ABLE TO FIX THE RECALL. NOW I AM TRYING TO REGISTER MY VEHICLE WITH DMV AND I WAS TOLD ABOUT THE PROOF OF CORRECTION THAT I NEED TO PROVIDE FOR AN EMISSION RECALL. I CALLED MULTIPLE DODGE DEALERS WITH NO SUCCESS TO HAVE IT WORKED ON PLUS I WAS SUGGESTED TO CALL MERCEDES BENZ SINCE IT IS A MERCEDES ENGINEERED VEHICLE AND SINCE ITS A DODGE THEY WON'T DO THE RECALL. NOW I AM STUCK WITH A VEHICLE I CAN GET FIXED AND REGISTERED. THE VEHICLE IS MY WORK VEHICLE AND I CAN'T DO ANY WORK/INCOME BECAUSE IT CAN'T BE REGISTERED.PLEASE ADVICE

NHTSA ID

11173311

Incident

Jan 24, 2019

Mileage

300,000 mi

CRANKSHAFT POSITION SENSOR FAULTY, CHECK ENGINE LIGHT COMES ON UPON STARTUP.

NHTSA ID

11152252

Incident

Nov 1, 2014

Mileage

110,000 mi

ENTIRE MERCEDES DIESEL SPRINTER ENGINE FAILED COMPLETELY AND WILL NEED A NEW ENGINE. POSSIBLE CAUSE IS CRACKED PISTON OR STUCK INJECTOR. THIS HAPPENED WHEN DRIVING, SHORTLY AFTER SERPENTINE BELT AND TRANSMISSION LINE WERE REPLACED, VEHICLE WAS JUST SERVICED, INCLUDING NEW BRAKES, MUFFLER, INSPECTION, OIL CHANGE. ONLY 82,000 MILES! COST WILL BE OVER $11,000! THIS IS A WINNEBAGO VIEW AND ALTHOUGH IT IS NOW OLDER (2007) IT HASN'T BEEN DRIVEN THAT MUCH EACH YEAR.

NHTSA ID

11114523

Incident

Jul 5, 2018

Mileage

82,000 mi

TL* THE CONTACT OWNS A 2006 DODGE SPRINTER 3500. THE CONTACT STATED THAT THE CHECK ENGINE WARNING INDICATOR ILLUMINATED AND THERE WAS A RANDOM FAILURE IN WHICH A LIMP MODE OCCURRED AND CAUSED A DRASTIC REDUCTION IN SPEED. THE VEHICLE WAS COASTED TO MERCEDES-BENZ OF PALM SPRINGS (4095 E PALM CANYON DR, PALM SPRINGS, CA 92264, (760) 328-6525) WHO REPLACED THE EGR AND PROVIDED DIAGNOSTIC TESTING. THE FAILURE CONTINUED TO PROGRESS INTERMITTENTLY. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO REPLACED THE EGR AND ADDITIONAL PARTS. THE PART WAS REPLACED A THIRD TIME DUE TO THE FAILURE. THE VEHICLE WAS ALSO SERVICED FOR A MANUFACTURER RECALL (T21) AT HILLTOP CHRYSLER JEEP DODGE RAM (3291 AUTO PLAZA DRIVE, RICHMOND, CA 94806, (510) 243-6100). THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED. THE FAILURE MILEAGE WAS NOT AVAILABLE.

NHTSA ID

11054714

Incident

Mar 6, 2015

SPRINTER IN LOOSING POWER WHEN ITS GOING TO EVEN LITTLE HILL,AFTER THAT WORKS FINE.CHK WITH SHOP TRANS OK. OTHER SITUATION IS AC VENTS GIVING ONLY COLD AIR FROM TOP VENTS AND SIDE VENTS GIVING FULL HEAT LIKE OVER HOT.

NHTSA ID

11015847

Incident

Jun 11, 2017

Mileage

73,000 mi

EGR Valve Diagnosis & Cleaning (and EGR Cooler Cleaning) – OM642, Sprinter 906/907 Complaint Complaint A: The engine is jolting/bucking between 1700 and 1900 rpm. Complaint B: One or more mechanical related fault codes for EGR Valve stored in CDI control unit, with possible Check Engine Light. Review list of mechanical fault codes in table below. NOTE: If one or more electrical related fault codes for EGR Valve are also present in CDI, utilize Complaint C. Review list of electrical fault codes PDF document in attachments. Complaint C: One or more electrical related fault codes for EGR Valve stored in CDI control unit, with possible Check Engine Light. Review list of electrical fault codes PDF document attached. NOTE: This LI supersedes LI14.20‑N‑073813, which is no longer valid. Cause Cause of Complaint A: Increased friction between the EGR Valve blade and seat due to soot deposits causing a delay of the EGR Valve being able to reach the target value of the EGR Valve position controller. NOTE: This causes the EGR Valve blade and potentially the boost pressure controller to oscillate. Cause of Complaint B: Soot deposits between the EGR Valve blade and seat leading to the EGR Valve no longer being able to meet the desired target of the EGR Valve position controller. Cause of Complaint C: Internal EGR Valve or other electrical faults related to the EGR Valve function.

Acoustic Warning or message occurring when a closed sliding door is not recognized Complaint Customer may state the warning message or indicator accompanied by acoustic tone alerting the sliding door is ajar when the door is completely closed Cause There are several reasons that lead to the failure occurring: ‑ Mechanical damage through bending when loading and unloading ‑ Worn contact plates ‑‑> After detachment of silver plating, the coper plate is corroded ‑ Movement of sliding door/body when driving ‑‑> Contact pins do not always make contact with contact plate ‑‑> Central locking system fault message in instrument cluster Remedy In a problem case, replace contact switch for vehicles with +T50/+T55/+EL9 or contact plate with A4478201903 Check the fit of the sliding doors here and make any necessary adjustments as per AR72.16‑S‑1023E (447 /448) and AR72.16‑D‑1023TS (907/910). Further valid damage codes: 82326 Contact switch for central locking system on sliding door 82347 Contact plate for central locking system on sliding door 53196 K/Z contact plate for central locking system on sliding door 82645 Contact switch for sliding door

Unavailability of MB Apps Complaint A popup is seen on the HU with the message "data connection temporarily not available". Cause MB Apps is officially sundowned for all vehicles with NTG5 Head Unit Variant. Remedy No support available for NTG5 Head Unit Variants for MB App related topics.

Complaint While driving through muddy / sandy/ off road terrain "4Matic Currently Unavailable" message on the dash Cause This vehicle is not equipped with a fixed force distribution AWD, rather force is only applied to the front axle according to ESP calculations. As per GF28.00‑D‑ 9900A: "vehicles with 4MATIC all‑wheel system and variable force distribution, an electronically regulated multiplate clutch integrated into the transfer case provides for the torque distribution. If the multiplate clutch is open during normal driving operation, only the rear axle drives the vehicle. If the clutch is closed, the front axle comes into play." The message "All‑wheel drive temporarily unavailable" is not indicative of a malfunction but rather informs the driver that all‑wheel drive is currently not available due to the transfer case clutch overheating. This occurs when the vehicle is driven in such a way that maximum front axle torque is needed for an extended period, causing the clutch to get excessively hot. If the vehicle is being driven under heavy load conditions, like in deep sand or snow, the rear axle may slip while the front axle does not deliver power. The transfer case then attempts to distribute torque to correct the slip, but it is limited to a maximum of 1150 Nm to protect the front axle transmission. In extended heavy‑load scenarios, the multidisk clutch in the transfer case slips, increasing the temperature. If the temperature model detects a critical temperature of 240°C, the system protects itself by disconnecting until it cools down to around 160°C, after which the all‑wheel drive becomes available again and the warning message disappears.Vehicles can handle flat terrain easily, but steep slopes or situations where wheels slip might cause additional resistance, leading to the described protection events and message in the dash. Remedy Recommendation is to release the vehicle back to the client with an explanation that the vehicle is operating as designed. Please advise the client to limit vehicle acceleration in limited traction situations to avoid disabling of the 4Matic system ‑ please see "Notes on all‑wheel drive" provided in the operators manual.

ASSYST PLUS service reminder appears earlier than expected due to vehicle operating conditions Complaint The ASSYST PLUS service reminder appears earlier than expected. The customer or dealer may report that the vehicle did not reach the starting maintenance interval shown in vehicle documentation, option coding, sales literature, or the Owner's Manual. The service reminder may appear significantly earlier than anticipated even though no faults are stored and no malfunction is present in the vehicle. The remaining distance and remaining time continue to decrease normally until the service reminder is displayed. Cause This condition is not caused by a malfunction of ASSYST PLUS. ASSYST PLUS is a dynamic maintenance management system that continuously evaluates vehicle usage and opera-ting conditions to determine maintenance requirements. The starting maintenance interval specified by variant coding represents a maximum interval that may only be achieved under favorable operating conditions. Actual maintenance intervals may be significantly shorter depending on vehicle use. Vehicle operating conditions such as driving conditions, engine load, engine operating conditions, idling, short-trip operation, environmental influences, oil aging, and Diesel Particulate Filter (DPF) regeneration activity may reduce the maintenance interval from its starting value. These conditions may accelerate engine oil aging through increased soot loading, fuel dilution, moisture accumulation, and additional engine operating stress. As a result, the remaining distance and remaining time until the next service may be reduced from the starting maintenance interval. Remedy Do not replace any parts. A due service must be assumed if the maintenance data calculated by ASSYST PLUS indicates that service is required.

Complaint Complaint A: The engine is jolting/bucking between 1700 and 1900 rpm. Complaint B: One or more mechanical related fault codes for EGR Valve stored in CDI control unit, with possible Check Engine Light. Review list of mechanical fault codes in table below. NOTE: If one or more electrical related fault codes for EGR Valve are also present in CDI, utilize Complaint C. Review list of electrical fault codes PDF document in attachments. Complaint C: One or more electrical related fault codes for EGR Valve stored in CDI control unit, with possible Check Engine Light. Review list of electrical fault codes PDF document attached. NOTE: This LI supersedes LI14.20-N-073813, which is no longer valid. Cause Cause of Complaint A: Increased friction between the EGR Valve blade and seat due to soot deposits causing a delay of the EGR Valve being able to reach the target value of the EGR Valve position controller. NOTE: This causes the EGR Valve blade and potentially the boost pressure controller to oscillate. Cause of Complaint B: Soot deposits between the EGR Valve blade and seat leading to the EGR Valve no longer being able to meet the de-sired target of the EGR Valve position controller. Cause of Complaint C: Internal EGR Valve or other electrical faults related to the EGR Valve function. Remedy Remedy for Complaint A: Perform the following steps: 1. Disable the EGR Valve (Y27/17) by disconnecting the electrical connector. 2. Perform a test drive to check if the jolting/bucking issue resolves. 3. If the jolting/bucking is resolved, proceed to Remedy for Complaint B. 4. If jolting/bucking is still present, proceed with diagnosis to determine the root cause. Consider checking the follo-wing, but not limited to: •EGR system including the EGR Cooler, EGR Bypass Flap, EGR Temperature Sensor, and pipes for proper operati-on, excessive sooting and/or clogging, as well as EGR Bypass Flap vacuum element, switchover valve, and vacuum system. •Visually check the leak oil line or T-piece; reference LI07.00-N-059118.