2020 Freightliner Sprinter 2500

The Cooling fan behind the radiator also known as the clutch fan fell off the water pump. I realized it before it fell on the highway during rush hour and caused a major accident and engine failure. This is a very common problem and is all over the internet. In most cases it will take out the radiator, fan assembly, belts and hoses as reported by many on the internet when you google “MB sprinter clutch fan falls off”.

NHTSA ID

11685330

Incident

May 23, 2025

On May 22, 2023 around 19:00 after driving my vehicle for nearly 90 minutes the vehicle no longer responded to the gas pedal being depressed by increasing acceleration. The vehicle would not go over 2,500 RPMs even with the gas pedal fully depressed. No warning were shown on the driver display or in the messaging system. The manual gear shifting did not work to raise or lower the gears while the vehicle was in this state. The vehicle display showed the vehicle in "D" for Drive and I could not change it to any other value such as D1, D2, etc.. The vehicle had almost no power and would not accelerate except for very slowly taking over 1.5 minutes to reach 55 mph. This is a SEVERELY dangerous situation as without warning my vehicle stopped responding to driver input in a reasonable fashion and thus if I was attempting to turn onto a busy road or cross a road my vehicle would not have enough acceleration to do so and could cause an accident resulting in serious death or injury. No warnings or alerts were shown on driver console. Parking assistance was turned off. Lane departure was turned off. I cycled on/off the cruise control to no avail. I evened turned the engine off and on and the problem still persisted. It wasn't until I was able to safely pull off later and power off the vehicle and wait 5 minutes that the problem went away. It is incomprehensible to me why we allow car manufacturers to override user input and commands with faulty and buggy computer software. If I press the gas pedal it should respond!

NHTSA ID

11523457

Incident

May 22, 2023

Engine destroyed by oil and water accumulation in intercooler that was pulled through the turbo and entered cylinder 6. Bent connecting rod on Cylinder 6, Bent and torn turbo vanes. Sudden loss of power while operating. Mercedes is replacing the entire motor. No Symptoms before the event, check engine light after first restart.

NHTSA ID

11503674

Incident

Dec 29, 2022

Driving in center lane of three lane interstate highway in the evening so it was dark. I had cruise control set at 55 mph. Nothing to my right and at least 100 yards of nothing in front of me. A white sedan speeds by in the left lane staying entirely in their left lane. My vehicle slammed on the brakes for some unknown reason almost causing the vehicle behind me to collide with me. A red triangle appeared on dash display for 2 seconds or so (not long enough to know what the computer thought happened ). No explanation given. No messages in drive computer. Absolutely awful. This could have caused a major accident and it was all done by a computer with no explanation. I want a dealer to download the log from my car for 17:52-17:53 on 1/14/23 and issue a complete and detailed report. There’s a severe safety issue and it must be fixed.

NHTSA ID

11501821

Incident

Jan 14, 2023

I am experiencing cold start hesitation and unresponsive throttle at high elevation. The vehicle takes up to 20-30 seconds to accelerate, and puts me in a dangerous situation (in a highway intersection, for example). Once the engine temperature is warm, this issue goes away.

NHTSA ID

11477168

Incident

Feb 15, 2022

The Lane Keep Assistant (LKA) as implemented is a severe safety flaw. The LKA only take input from lane markers on the road but fails to consider other issues such as other vehicles or construction. Several times on my most recent drive on interstate highways at 70-80 mph I was passing large semi trucks. The trucks drifted out of their lane and into my lane. I took emergency evasive action to steer my vehicle out of the way of the semi truck but the Lane Keep Assistant (LKA) noticed I was out of my lane and aggressively steered my vehicle back into the other vehicle. Luckily I did not hit the other vehicle but the LKA made avoiding other vehicles more difficult and could contribute to a collision if the driver is not foreful enough to both steer out of the way of danger and to counter the steering control of the LKA. 1. This feature should not be allowed on vehicles as implemented. In my 30 years of the driving this is the most dangerous feature I have ever experienced. My vehicle is trying to kill me!! 2. This feature should have the ability to be set to "off" permanently or tied to a driver's profile settings to remain off while that driver is in control. Drivers should not have to remember to turn off the feature manually every time the car is started. 3. Driver's should have the ability to turn off steering control but still have the lane departure warning signal.

NHTSA ID

11421862

Incident

Jun 15, 2021

COLOR INSTRUMENT CLUSTER INCLUDING COLOR DISPLAY BETWEEN THE SPEEDOMETER AND TACHOMETER WILL NOT DIM AT NIGHT. THE RESULTING WASH OF LIGHT MAKES SEEING OUT THE SIDE MIRRORS OR ANYTHING AT NIGHT VERY DIFFICULT. VAN IS NOT SAFE TO DRIVE AT NIGHT. MANUFACTURE CONFIRMS THE PROBLEM BUT HAS NO FIX.

NHTSA ID

11389057

Incident

Nov 10, 2020

Mileage

300 mi

Model 907 with all-wheel drive (A4M) – All-wheel drive inoperative Complaint The customer may report one or more of the following: • All-wheel drive is unavailable or inoperative. • Rear wheel slip during acceleration on low-traction surfaces. • Noise from the front axle area while driving. • Message in the instrument cluster indicating all-wheel drive is unavailable due to overheating. • Fault code P27874B - The temperature of the clutch is too high. There is a fault due to overtemperature may be stored in control unit N15 (Transfer Case). Cause An internal failure of the front axle differential may result in loss of torque transfer to the front wheels. In some cases, a fracture of the weld between the crown gear and differential housing may be present. Remedy Replace the front axle differential in accordance with: AR33.30-D-0525TSY – Replace Front Axle Differential.

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.

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

Vehicles with SCR Generation 4: SCR/AdBlue® warning message cannot be reset with fault code P13DF00 or P300685 Complaint Vehicles with SCR Generation 4: SCR/AdBlue® warning message cannot be reset. Information: All fault codes in the AdBlue® (SCR) control unit have been processed and corrected; however, fault codes P13DF00 and P300685 remain active and stored in the AdBlue® (SCR) control unit. Cause The procedure for resetting the SCR/AdBlue® warning message with XENTRY Diagnosis has not been carried out. Information: Before resetting the SCR/AdBlue® warning message for SCR Generation 4, the AdBlue® system must be in proper working condition and tested.

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.