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

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.

OM642 DPF Filter Cracked or Broken Complaint Vehicle will not start or exhibits noisy exhaust. Check Engine Lamp (CEL) is on. Multiple control unit communication and system faults may be present, including but not limited to: 134800, 134900, 11B300, 11EC00, 15E100, 155700, 162500. Additional events codes may include: 134300, 102200, 163400, 16CE00. In many cases, multiple unrelated faults are stored due to electrical disruption from wiring damage rather than indivi-dual component failure. Cause The DPF filter is cracked, broken, or leaking, allowing hot exhaust gas to escape from the exhaust system. Depending on the location of the break or leak, hot exhaust gas may be directed toward the main wiring harness and/ or the SCR (Selective Catalytic Reduction) dosing valve assembly. This heat exposure can result in: • Internal melting of wiring insulation within the harness • Short to ground conditions and loss of communication between control units • Damage to the dosing valve and/or heated AdBlue line Damage to the wiring harness may not be visible externally, as the outer tape can remain intact while the internal wires are melted and fused together. Remedy Inspect the DPF assembly for cracks, separation, or leakage. Do not proceed with further diagnosis or component replacement until the exhaust leak source has been identified and confirmed. If any damage is found, replace the DPF filter assembly. Based on the location of the failure, inspect all components in the path of the exhaust leak, including the dosing valve assembly and main wiring harness. The wiring harness must be opened in any area exposed to the exhaust leak to visually inspect the individual wires. External inspection alone is not sufficient to determine harness condition. Repair or replace any damaged wiring in accordance with approved repair procedures. Replace any dosing system components that show signs of heat damage. Failure to identify and repair all heat-affected components will result in repeat faults or no-start conditions.

Complaint Rattling noise from underneath the vehicle. Cause One or more of the following conditions may be present: 1. The exhaust bracket from the DPF to the transmission is cracked or broken. • See Pic. 1 for an example of a broken bracket. 2. Transmission bell housing cracked or broken at the exhaust mounting area. • See Pic. 2 for an example of bell housing damage. 3. Exhaust bracket from DPF to engine (cylinder crankcase) cracked or broken. • See EPC OM651 #217 for bracket location. 4. Diesel Particulate Filter (DPF) pipe cracked at a weld joint. • Cracking may be present at bracket welds or along the DPF housing seams. • This can cause rattling noises and secondary exhaust bracket stress. • Perform a visual inspection of the DPF pipe and weld joints. Remedy Inspect all related components and repair or replace as required. Inspection and Repair 1. Inspect the exhaust bracket from the DPF to the transmission. • Check the bracket for cracks or complete separation. • See Pic. 1 for a failed example. • See EPC OM651 #550 and Pic. 3 for bracket location. • If damaged, replace the bracket. • See Pic. 4, Pic. 5, and Pic. 6 for the updated bracket design and identification. 2. Inspect the transmission bell housing. • Inspect the bell housing at the exhaust mounting point for cracks or structural damage. • See Pic. 2 for an example of bell housing damage. • Replace the transmission if damage is confirmed. 3. Inspect the exhaust bracket from the DPF to the engine (cylinder crankcase). • Inspect the bracket for cracks or broken mounting points. • See EPC OM651 #217 for bracket location. • Replace the bracket if damaged. 4. Inspect the DPF pipe. • Inspect the DPF for cracks at weld joints, especially near mounting points. • If cracking is found, replace per current aftertreatment guidelines. Correct positioning and tightening of the exhaust system are critical to prevent repeat failures. Positioning the Exhaust System 1. Position and align the exhaust system before tightening. • Support and fit the exhaust system in its installed position. • Push the exhaust system forward. • Install the DPF‑to‑transmission bracket and lightly tighten the mounting bolt. • Install the engine mount and V‑mount bolts by hand, approximately two turns. • See “Positioning of the exhaust system” image. Tightening Sequence 1. Tighten the exhaust system in the correct sequence. • Tighten engine mounting bolts to 25 Nm. • Tighten V‑mount bolts to 25 Nm. • Tighten exhaust bracket bolts to 15 Nm. • See “Tightening sequence of the exhaust system” image. 2. Verify mounting bolt locations. • Confirm correct mounting screw positions at the transmission bracket. • See Pic. 7 and Pic. 8 for mounting screw locations.

The check engine light is illuminated, or the AdBlue warning is active, with recorded faults related to AdBlue quality or concentration. Complaint Customer reports an illuminated check engine light and or an AdBlue system warning indicating AdBlue quality out of specification. The vehicle may enter reduced performance mode. One or more of the following fault codes related to the AdBlue tank may be stored: P206B31: Malfunction of the concentration sensor for AdBlue; the signal is absent. P203B31: Malfunction of the AdBlue fill level sensor; the signal is absent. P300494: The quality of the AdBlue is insufficient. Background AdBlue must meet ISO 22241 quality requirements. ISO 22241 urea content limits for AdBlue are 31.8 percent to 33.2 percent by mass. AdBlue begins to crystallize and freeze at approximately 12 degrees F. Freeze-thaw does not degrade the product when uncontaminated, and the bulk concentration returns to normal after complete thaw and mixing. Cause In cold soak conditions and during freeze thaw exposure, the tank contents may not be uniform at the time of sampling or system checks. During freezing and partial thaw, ice formation can temporarily create concentration gradients in the tank. As a result, urea percent readings can vary based on sample location and the state of thaw and mixing, which can produce apparent out of range readings even though the bulk fluid returns to normal after mixing. Remedy Testing Do not use a single urea percent reading taken from frozen, partially frozen, or not fully mixed AdBlue to make a repair or responsibility decision. Confirm full thaw and ensure tank contents are mixed before sampling. 1. Confirm full thaw - Confirm the AdBlue tank and associated components are fully thawed before sampling. - Do not sample slushy or partially frozen fluid. 2. Mix tank contents - Perform a road drive intended to mix the tank contents before sampling. - Idle time alone is not a reliable substitute for mixing. 3. Sample and measure - Take the sample and measure with the MB refractometer per the MB tool instructions. - Record the urea percent value. 4. Interpret the result against ISO 22241 limits - Within specification is 31.8 percent to 33.2 percent urea by mass. 5. Repeat if out of specification - If out of specification, repeat after an additional mixing drive to reduce sampling variation. - If still out of specification after full thaw, mixing, and repeat measurement, treat as a true out of specification result and proceed with further diagnosis per applicable MB guidance. Acceptance criteria AdBlue is within the ISO 22241 specification when the urea percent is between 31.8 percent and 33.2 percent by mass. Values outside this range are out of specification and require further diagnosis after completing the full thaw and mi-xing procedure above. Cross reference For vehicles with fault codes P206B31, P203B31, or P300494, refer to LI49.20-N-078838 for the detailed diagnostic and repair procedure. If a SCR or AdBlue warning reset is required after correction, refer to LI49.20-N-075995. Complete the diagnostic and corrective steps first. Perform the warning reset only after the underlying fault condition has been corrected. Warranty information and claim handling

EGR Valve Diagnosis & Cleaning (and EGR Cooler Cleaning) – OM642, Sprinter 906/907 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. 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.