2008 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.

We've had multiple issues with starting the vehicle. After number attempts to eradicate the issue, I Google searched the problems and found that the y connect harness from battery to alternator and starter had been remanufactured for improvement 3 times. I'm uncertain why this part did not have a recall for my vehicle. Mercedes manufacturer for our motor should be responsible for this issue since there have been so many reported issues with this part. Can you please evaluate the complaint and advise.

NHTSA ID

11652459

Incident

Apr 3, 2025

Dodge was not able to replace the passenger airbag. No dealers could replace it. I had the passenger airbag replaced by a Mercedes Sprinter dealership and was reimbursed by Dodge. The problem is they can not remove the recall from NHTSA. I still get email and mail telling me to replace the passenger airbag. I've called 4 times over 2 years. Each time they say they'll fix it. It still shows the recall is not complete. How can I remedy this? Dodge has been no help.

NHTSA ID

11648837

Incident

May 1, 2023

The contact owns a 2008 Dodge Sprinter 3500. The contact stated while driving 65 MPH, the contact noticed that several unknown warning lights were illuminated and suddenly the vehicle failed to accelerate. The vehicle decelerated to 10 MPH with the accelerator pedal depressed to the floorboard. The contact pulled the vehicle into a parking lot, restarted the vehicle and the vehicle temporarily operated as designed before the failure recurred. The contact had the vehicle towed to a local dealer to be diagnosed. The mechanic was unable to duplicate the failure but retrieved a failure code for the ABS control module. The contact was informed that the ABS control module needed to be replaced. The ABS control module was replaced however, the failure code remained. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was unknown,

NHTSA ID

11430652

Incident

Aug 1, 2019

THE DODGE DEALER IN BELLEVUE WASHINGTON REFUSED TO PERFORM THE RECALL REPAIRS. THEY CLAIMED IT WAS BECAUSE THEY COULDN'T PUT THE VEHICLE ON THEIR LIFT, EVEN THOUGH AIRBAG REPLACEMENT DOESN'T REQUIRE THAT. THEY REFERRED ME TO SEATTLE MERCEDES, WHICH ALSO REFUSED TO DO THE RECALL.

NHTSA ID

11222013

Incident

Jun 17, 2019

TAKATA RECALL. THE DRIVERS SIDE AIR BAG WAS REPLACED OCT 12 2017. IN 01/2018 I GET A RECALL FOR THE PASSENGER SIDE AIR BAG. I CALLED FREIGHTLINER BUT WAS TOLD THEY CAN NO LONGER REPLACED THE AIRBAG IN NEW YORK STATE AND THEY WOULD GET BACK TO ME. THEY NEVER DID. NY DMV SENT ME A NOTICE SO I CALLED FREIGHTLINER AND THEY SHOW NO RECALLS SAME AS YOUR WEBSITE. WHAT HAPPENED? HOW CAN I GET THE AIRBAG REPLACED NOW? *DT *DT

NHTSA ID

11221561

Incident

Jan 1, 2018

TAKATA RECALL I MADE 2 ATTEMPTS TO CONTACT WEST VALLEY DODGE IN CA IN WHICH DIDN'T GET A CALL BACK. I MADE APPT ON 11/9 AT SIMI DODGE IN CA. I TOLD THEM I HAD A DODGE SPRINTER ON A B CLASS RV. I WAS TOLD NO PROBLEM. WHEN I SHOWED UP FOR APPT THEY TOLD ME THEY COULDN'T DO IT BECAUSE OF TOOLS NEEDED. I LOOKED ON LINE AND NO SPECIAL TOOLS ARE NEEDED. AS I SUSPECTED THEY JUST DIDN'T WANT TO DO THE WORK. A COMPLETE WASTE OF MY TIME.

NHTSA ID

11150329

Incident

Nov 9, 2018

TAKATA RECALL WE HAVE EXPERIENCED A TOTAL OF 3 RECALLS ON THIS VEHICLE. THE FIRST RECALL WAS 2016 ON THE PASSENGER SIDE. THE SECOND RECALL IN 2017 ON THE DRIVERS SIDE. THE THIRD MOST IMPORTANTLY WAS A RECALL ON THE 2016 RECALL THE PASSENGER SIDE. FOR ALMOST 2 YEARS THE U.S. RECALL CENTER KEPT SENDING OUT WARNINGS BUT NEVER CLEARLY STATED IT WAS A RECALL ON A RECALL. AS CONSUMERS, WE WOULD CALL TO ASK QUESTIONS TO CLARIFY THIS.. ONLY TO HAVE THEM TAKE DOWN INVOICES AND DATES ON WHEN THE AIR BAGS WERE REPLACED AND PROMISING THIS WAS NOTED AND FULFILLED THEIR NEED TO SEND US A NOTICE. SOON AFTER, WE WOULD GET MORE NOTICES VIA MAIL AND ALSO PHONE MESSAGES. WE HAD 2 DIFFERENT CONFERENCE TELEPHONE CALLS WITH DODGE/RECALL CENTER/AND US, THE [XXX]'S... AND WERE TOLD THE PROBLEM WAS RESOLVED. HAVING SAID THAT IT WAS NOT. FINALLY A SMART SERVICE DEPT. MANAGER AT DODGE FOUND THE ERROR AND RECTIFIED IT. HE SAID. HERE IN LIES THE PROBLEM, YOU HAVE ANOTHER RECALL ON THE 2016 RECALL. REALLY? SINCE FIXING THIS, I HAVE NOTIFIED THE CALL CENTER, VIA PHONE TO BRING TO THEIR ATTENTION. I THINK IT NEEDS TO BE DOCUMENTED NOW. IT IS IMPARATIVE THAT WHEN IT IS A RECALL OF A PREVIOUS RECALL. SOMEONE NEEDS TO PAY ATTENTION. MANY CONSUMERS, LIKE WE ALMOST DID, WILL JUST IGNORE THESE SECOND NOTICES. WE THROW AWAY THE NOTICES BECAUSE WE ARE TOLD AND BELIEVE THIS IS ALREADY REPAIRED. IT WAS NOT. SO PLEASE, FOR YOUR OWN SAKE, MAKE ADJUSTMENTS TO THIS PROBLEM BEFORE YOU ARE ADDRESSING LIVES LOST DUE TO MISINFORMATION. RECALL ON PREVIOUS RECALLS ARE INDEED HAPPENING AND ARE VERY DANGEROUS IF LEFT UNANSWERED. YOU CAN THANK ME NOW OR JUST PAY FOR NEEDLESS DEATHS LATER. YOUR WELCOME. [XXX] VANCOUVER, WASHINGTON. [XXX] CALL ONLY IF YOU HAVE A TRUE, VALID QUESTION. IF NOT, NO NEED TO CALL AT ALL. HAVE A GOOD DAY. *JS PARTS OF THIS DOCUMENT HAVE BEEN REDACTED TO PROTECT PERSONALLY IDENTIFIABLE INFORMATION PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).

NHTSA ID

11141588

Incident

Jun 15, 2016

VEHICLE IN MOTION. PROGRESSIVELY WORSE VIBRATION TO THE POINT OF REQUIRING A TOW. UPON INSPECTION AT EDDIE'S TRUCK REPAIR, RAPID CITY, SD FOUND INNER LEFT REAR ("DUAL") WHEEL BROKEN BETWEEN ALL HOLES AND SLOTS IN CENTER OF WHEEL. NO OBVIOUS CAUSE. NO DAMAGE TO WHEELS OR TIRES. ALL TIRES PROPERLY INFLATED. ALL LUG NUTS TIGHT, PROPERLY TORQUED. BREAKS APPEAR NEW -- NO RUST. EVIDENCE OF BROKEN SECTIONS RUBBING ON EACH OTHER, HAD THIS BEEN A SINGLE WHEEL (NOT DUALS) THIS FAILURE MIGHT HAVE RESULTED IN A CATASTROPHIC ACCIDENT. THE FACT THAT THE OUTER WHEEL AND TIRE WERE IN GOOD CONDITION ALLOWED US THE TIME TO PULL OVER.

NHTSA ID

11132343

Incident

Sep 20, 2018

Mileage

89,000 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.