2007 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 2008 Winnebago View RV built on a 2007 Dodge Sprinter 3500 Chassis. The contact stated that the key fob failed to open the doors of the recreational vehicle. The contact stated that he attempted to replace the batteries however, the failure continued. The contact went to an unknown Dodge dealer who informed him that he would need to go to a Mercedes- Benz dealer for a key fob code. The contact stated that he was informed that the codes were located and Mercedes-Benz in Europe; and the USA dealers were unable to get the codes. The contact stated that the key fob needed a software update and code to work. The manufacturer Mercedes-Benz complaint department was contacted and a case was opened. The approximate failure mileage was 60,000.

NHTSA ID

11455688

Incident

Mar 8, 2021

Mileage

60,000 mi

WHILE DRIVING ON INTERSTATE 40 IN ARIZONA, THE DODGE LOST POWER AND THE ABS LIGHT CAME ON ALONG WITH THE ESP LIGHT AND BRAKE LIGHT. WHEN LIGHTS ILLUMINATED THE ENGINE LOST POWER AND WENT INTO LIMP MODE THAT SIGNIFICANTLY REDUCED SPEED. ONCE THAT HAPPENED A SEMI WAS BEHIND ME AND HE HAD TO SLAM ON HIS BRAKES. I WAS ABLE TO PULL RV OVER AND LET IT REST. AFTER 2 HOURS OF BEING ON SIDE OF HIGHWAY, I WAS ABLE TO GET RV STARTED AND BACK ON THE ROAD. I FIXED THE REAR SPEED SENSORS AND TRIED DRIVING RV AGAIN. SAME ISSUE. I WAS ON INTERSTATE 17 WHEN THE 3 LIGHTS ILLUMINATED AND THE RV STALLED COMPLETELY. I HAD NO POWERING STEERING AND STRUGGLED TO SAFELY PULL OVER. RV WILL BE TAKEN BACK TO MERCEDES AND TRY TO TROUBLESHOOT. THERE NEEDS TO BE A RECALL AND MERCEDES NEEDS TO FIX THE ISSUE AS I SEE ON FORUMS THAT A LOT OF OTHER PEOPLE ARE HAVING THE SAME ISSUE. LUCKILY, I HAVE NOT HEARD OF ANY INJURIES BUT IF THIS ISSUE HAPPENS TO AN INEXPERIENCED DRIVER, THEY MIGHT PANIC AND CAUSE AN ACCIDENT.

NHTSA ID

11338967

Incident

Jul 12, 2020

Mileage

83,848 mi

COPY OF TEXT MESSAGE TO K AND M DODGE IN GRAND RAPIDS, MI WHO CURRENTLY HAS MY RV :MIKE BLATTNER AND MISSY WILLMAN, I NEED AN APPT TO DISCUSS MY DODGE SPRINTER CHASSIS RV THAT WAS TOWED 02/21/18 IN THERE BECAUSE IT WOULD NOT SHIFT OUT OF PARK. NICK WITH SERVICE SAID A BRAKE SWITCH AND THE BATTERY WERE NEEDED AND I AUTHORIZED THAT WORK, AND IT WAS COMPLETED. THEN NICK CONTACTED ME SAYING IT WOULD NOT SHIFT OUT OF PARK AND THAT A SHIFTER ASSEMBLY AND AN AMBIENT AIR SENSOR REPLACEMENT WERE NOW REQUIRED TO GET THE RV WORKING. THE SHIFTING PROBLEM IS WHY IT WAS ORIGINALLY TOWED IN. I AM FEELING THAT THE FOCUS OF MY CONCERNS WERE UNADDRESSED INITIALLY BY THE SERVICE DEPT. I SPOKE WITH THE PREVIOUS OWNER AND WAS TOLD THE BATTERY WAS NOT EVEN THREE YRS OLD, YET NICK SAID THAT THE BATTERY THEY TOOK OUT WAS NO LONGER THERE, THAT TWO DAYS AFTER IT WAS TAKEN OUT, IT WAS PICKED UP TO BE RECYCLED. WAS THE BATTERY STILL UNDER WARRANTY? WAS THE BRAKE SWITCH REPLACEMENT NECESSARY, SINCE IT DID NOT TAKE CARE OF THE SHIFTING PROBLEM AFTER THE SERVICE TECHNICIAN REPLACED IT? I WAS TOLD BY A MECHANIC TO MAKE A COMPLAINT WITH NHTSA AS THIS WAS A COMMON PROBLEM HE ENCOUNTERED WITH THE DODGE SPRINTER 3500. NHTSA AGENT, BEAU, GAVE ME AN ODI COMPLAINT #: 11078745, THEN RECOMMENDED I LOG A COMPLAINT WITH FCA NORTH AMERICA, WHICH I DID, AND WAS GIVEN A CASE # 33667091. I AM NOT HAPPY. I NEED TO MEET WITH YOUR K AND M MANAGEMENT TEAM TO ADDRESS MY CONCERNS.

NHTSA ID

11079048

Incident

Aug 13, 2017

Mileage

40,994 mi

TL* THE CONTACT OWNS A 2007 DODGE SPRINTER 3500. THE CONTACT STATED THAT HE TOOK THE VEHICLE IN TO BE SERVICED FOR THE NHTSA CAMPAIGN NUMBER: 15V354000 (AIR BAGS), HOWEVER THE DEALER INFORMED THE CONTACT THAT HE WOULD BE CHARGED FOR THE REMOVAL OF THE SCREEN ATTACHED TO THE WINDOW IN ORDER TO GET TO THE PASSENGER AIRBAG INFLATOR. THE RECALL REMEDY WAS NOT PERFORMED. THE MANUFACTURER WAS NOT MADE AWARE OF THE ISSUE. THE CONTACT DID NOT EXPERIENCE A FAILURE.

NHTSA ID

10968966

Incident

Mar 28, 2017

FOR THE SECOND TIME SINCE WE PURCHASED THE VEHICLE, THE TUBE CONNECTED TO THE EGR VALVE SPLIT APART. THE TUBE IS LOCATED DIRECTLY UNDER THE CAB AIR INTAKE, SO EXHAUST GASSES ARE PUMPED INTO THE CAB. WE WERE FORTUNATE THAT THE TUBE BROKE COMPLETELY APART AND THE PRESENCE OF EXHAUST WAS OBVIOUS. SINCE THIS HAS HAPPENED TWICE IN 85K MILES, I AM CONCERNED THE NEXT TIME IT MIGHT JUST CRACK AND CAUSE CARBON MONOXIDE POISONING. THE FAILURE OCCURRED ON INTERSTATE HIGHWAY 10 AT 65 MPH. ACCORDING TO THE SERVICE TECHNICIAN, THE TUBE RUPTURED BECAUSE THE EGR VALVE STUCK CLOSED, CAUSING PRESSURE TO BUILD UP IN THE TUBE. I HAVE ALL THE PARTS THAT WERE REPLACED AND CAN SHIP THEM TO YOU IF NECESSARY.

NHTSA ID

10947566

Incident

Dec 30, 2016

Mileage

85,000 mi

TL* TAKATA RECALL. THE CONTACT OWNS A 2007 DODGE SPRINTER 3500. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 15V354000 (AIR BAGS); HOWEVER, THE PARTS TO DO THE RECALL REPAIR WERE NOT AVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. THE MANUFACTURER WAS NOTIFIED OF THE ISSUE. THE CONTACT HAD NOT EXPERIENCED A FAILURE. PARTS DISTRIBUTION DISCONNECT.

NHTSA ID

10920284

Incident

Sep 11, 2016

PASSENGER AIRBAG RECALL OF APPX. 2 YEARS AGO AS OF 8/29/2016 HAS NO REPLACEMENT FOR THE RECALLED AIRBAG LEAVING THE PASSENGER IN DANGER OF INJURY OF DEATH IF AND WHEN THE PRESENT AIRBAG IN THE 2007 SPRINTER DODGE CHASSIS DEPLOYS. REPLACEMENT OF AIRBAG MUST BE DONE IMMEDIATELY.

NHTSA ID

10899244

Incident

Aug 29, 2016

TL* THE CONTACT OWNS A 2007 DODGE SPRINTER 3500. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBERS: 15V354000 (AIR BAGS) AND 16V077000 (AIR BAGS); HOWEVER, THE PARTS FOR THE RECALL REPAIRS WERE UNAVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIRS. THE MANUFACTURER WAS NOT MADE AWARE OF THE ISSUES. THE CONTACT HAD NOT EXPERIENCED A FAILURE. PARTS DISTRIBUTION DISCONNECT AND VIN TOOL CONFIRMS PARTS NOT AVAILABLE. UPDATED 10/04/16*LJ UPDATED 08/09/2017 *JS

NHTSA ID

10896856

Incident

Aug 18, 2016

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.