2003 Freightliner Sprinter 2500

TL* THE CONTACT OWNED A 2003 N/A FREIGHTLINER SPRINTER VAN. THE CONTACT STATED THAT WHILE DRIVING AT 65 MPH, THE VEHICLE BEGAN TO LOSE SPEED, THAN THE VEHICLE BEGAN TO SHUTTER AND THE CONTACT LOOKED THRU THE REAR PASSENGER SIDE VIEW MIRROR AND NOTICED BLACK SMOKE COMING FROM EXHAUST. THE CONTACT MERGED TO THE SIDE OF THE ROAD. THE CONTACT PUT THE VEHICLE IN PARK AND EXITED OUT OF THE VEHICLE. THE CONTACT WENT TO THE FRONT OF THE VEHICLE WHEN IT WAS NOTICED FLUID WAS SPILLING OUT OF THE VEHICLE AND SMOKE COMING FROM UNDERNEATH THE HOOD. THE CONTACT WENT TO RECEIVE THEIR FIRE EXTINGUISHERS AND OPENED THE HOOD AND NOTICED FIRE COMING FROM UNDERNEATH THE AND STARTED TO EXTINGUISH THE FIRE BUT DID NOT FULLY PUT OUT THE FLAMES. THE CONTACT THEN HAD HIS WIFE AND FOUR CHILDREN EXIT OUT OF THE VEHICLE AND WAITED FOR THE FIRE DEPARTMENT TO COME TO THE SCENE. THE FIRE DEPARTMENT DID COME OUT AND EXTINGUISHED THE FIRE FULLY. A FIRE REPORT WAS FILED. NO ONE WAS INJURED. THE VEHICLE WAS TOWED TO A NEAR BY TOWED LOT.THE CONTACT CALLED THE VEHICLE MANUFACTURER TO HAVE THEM TOW THE VEHICLE TO THEIR LOCAL DEALER TO HAVE INSPECTED AND DIAGNOSED OF THE FAILURE BUT THE MANUFACTURER DECLINED DO THAT SO THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE CONTACT DOES NOT KNOW IF THE VEHICLE DEEMED A TOTAL LOSS OR IF THE THAT TOWED LOT SCRAPPED THE VEHICLE FOR PARTS. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 93,000. ## VIN PASSED ## SPRINTER (DODGE OR FREIGHTLINER) 2003 ##

NHTSA ID

11405848

Incident

Jun 19, 2019

Mileage

93,000 mi

TL* THE CONTACT OWNS A 2003 FREIGHTLINER SPRINTER 2500. THE CONTACT STATED WHILE DRIVING 14 MPH AND DEPRESSING THE ACCELERATOR PEDAL, THE VEHICLE FAILED TO RESPOND. THE CONTACT STATED THAT THE MASTER WARNING LIGHT WAS ILLUMINATED. THE CONTACT PARKED ON THE SIDE OF THE ROADWAY. THE VEHICLE WAS THEN SLOWLY DRIVEN BACK TO HIS RESIDENCE. THE CONTACT CALLED MERCEDES-BENZ OF LOUISVILLE LOCATED AT 2520 TERRA CROSSING BLVD, LOUISVILLE, KY 40245, (502) 896-4411, AND THE DEALER WAS MADE AWARE OF THE FAILURE. THE CONTACT CALLED AN INDEPENDENT MECHANIC AND MADE AN APPOINTMENT TO HAVE THE VEHICLE REPAIRED. THE VEHICLE WAS NOT DIAGNOSED NOR REPAIRED. UPON INVESTIGATION, THE CONTACT ASSOCIATED THE FAILURE WITH NHTSA CAMPAIGN NUMBER: 16V833000 (ELECTRICAL SYSTEM, SERVICE BRAKES, HYDRAULIC) HOWEVER, THE VIN WAS NOT INCLUDED. THE MANUFACTURER WAS NOT INFORMED OF FAILURE. THE FAILURE MILEAGE WAS 320,000.

NHTSA ID

11353145

Incident

Jul 21, 2020

Mileage

320,000 mi

VEHICLE EXPERIENCED REDUCED POWER AND WHOOSH SOUND. FOUND INTAKE MANIFOLD WITH CRACKS LEAKING EXHAUST FROM EGR RUNNER. MADE TEMPORARY REPAIR ON THE ROAD AND WAS ABLE TO RETURN TO SHOP. FOUND THERE WAS A RECALL ON THIS PART (2010-040002) BUT HAVE BEEN UNABLE TO GET REPAIR FROM DAIMLER VANS USA. *TR

NHTSA ID

10615198

Incident

Jul 7, 2014

Mileage

243,000 mi

TL* THE CONTACT OWNS A 2003 FREIGHTLINER SPRINTER 2500. THE CONTACT STATED AFTER RECEIVING A RECALL NOTICE FOR NHTSA CAMPAIGN NUMBER: 11V410000 (ENGINE AND ENGINE COOLING), THE CONTACT CALLED THE DEALER. THE DEALER STATED THAT THEY COULD NOT REMEDY THE VEHICLE DUE TO THE DEALER NOT BEING ABLE TO WORK ON VANS. THE CONTACT THEN CALLED THE MANUFACTURER TO FIND OUT WHERE TO TAKE THE VEHICLE. THE NEAREST DEALER WAS TOO FAR TO DRIVE FOR THE CONTACT. THE MANUFACTURER THEN STATED TO CALL FREIGHTLINER REGARDING THE RECALL. FREIGHTLINER INFORMED THE CONTACT THAT THEY WERE NOT RESPONSIBLE FOR THE REPAIR OF THIS VEHICLE. THE CONTACT HAD NOT EXPERIENCED A FAILURE.

NHTSA ID

10496777

Incident

Feb 7, 2013

TL* THE CONTACT OWNS A 2003 FREIGHTLINER SPRINTER 2500. THE CONTACT STATED AFTER RECEIVING A RECALL NOTICE, HE TOOK THE VEHICLE WAS TAKEN TO A LOCAL DEALER. THE DEALER STATED THE CONTACT HAD TO PAY TO HAVE THE RECALL REPAIR PERFORMED ON THE VEHICLE. THE CONTACT STATED THE RECALL SAID THE REMEDY WAS FREE OF CHARGE. THE CONTACT CALLED THE MANUFACTURER TO VERIFY. THE FAILURE MILEAGE WAS 330,000. UPDATED 07/05/12*LJ THE DEALER CONFIRMED THE INTAKE MANIFOLD REPLACEMENT WAS COVERED BY THE RECALL. HOWEVER, THE DEALER STATED THEY WOULD NEED TO REPLACE THE FUEL LINES, WHICH COULD BE DAMAGED DURING THE REMOVAL OF THE INTAKE MANIFOLD. THE CONSUMER WAS INFORMED IT WOULD COST $300 TO REPLACE THE FUEL LINES. UPDATED 07/10/12 UPDATED 07/19/12.

NHTSA ID

10461911

Incident

Jun 14, 2012

Mileage

330,000 mi

I RECEIVED A RECALL NOTICE FOR MY VEHICLE. I CONTACTED THE NUMBER IN THE LETTER TO HAVE THE PROBLEM CORRECTED. AFTER SPEAKING WITH A REPRESENTATIVE, I WAS INFORMED THAT THE CLOSEST REPAIR CENTER WAS 110 MILES AWAY. THE SERVICE CENTER WHERE THE WORK WOULD BE PERFORMED IS ONLY OPEN M-F, 7A-5P. IN ORDER FOR ME TO GET THE AFFECTED VEHICLE FOR REPAIRED, I WOULD HAVE TO TAKE OFF WORK AND LOSE A DAY'S PAY OR LONGER. THE REPRESENTATIVE OFFERED NO HELP IN OVERCOMING MY DILEMMA. *TR

NHTSA ID

10336376

Incident

Jun 15, 2010

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.