1999 Mercedes-Benz M Class

ANALYSIS OF COMPLAINTS TO ODI AND MERCEDES AND WARRANTY CLAIM DATA SUBMITTED BY MERCEDES INDICATES THAT THE ALLEGED DEFECT HAS OCCURRED AT A LOW RATE (36.5 COMPLAINTS PER 100,000 VEHICLES AND 0.29 PERCENT WARRANTY CLAIM RATE), WITH NO DISCERNABLE DEFECT TREND INDICATING THAT THE RATE OF CHAFING RELATED BRAKE LINE FAILURES IS INCREASING.THERE HAVE BEEN NO NEW COMPLAINTS SINCE JANUARY 2009.WHEN THE ANALYSIS IS LIMITED TO INCIDENTS OF BRAKE LINE LEAKAGE THAT RESULTED IN ALLEGATIONS OF REDUCED BRAKE EFFECTIVENESS, THE RATE DROPS EVEN FURTHER (22.3 COMPLAINTS PER 100,000 VEHICLES AND 0.04 PERCENT WARRANTY CLAIM RATE). MERCEDES PROVIDED DATA SHOWING THAT IN THE RARE INSTANCES WHEN CHAFING DID PROGRESS TO BRAKE LINE LEAKAGE THE DRIVER WOULD BE IMMEDIATELY ALERTED TO A PROBLEM BY ILLUMINATION OF THE BRIGHT YELLOW ESP/BAS WARNING LAMP AND CHANGES IN BRAKE PEDAL FEEL.CONTINUED OPERATION WITH A LEAKING BRAKE LINE WOULD RESULT IN ILLUMINATION OF THE BRIGHT RED BRAKE WARNING LAMP AND AN AUDIBLE CHIME DUE TO LOW MASTER CYLINDER RESERVOIR LEVEL. CONTINUED OPERATION WITH THE BRAKE WARNING LAMP ILLUMINATED WOULD ULTIMATELY DRAIN THE RESERVOIR FOR THE AFFECTED CIRCUIT, RESULTING IN LOSS OF THE CIRCUIT AND AN APPROXIMATELY 80% INCREASE IN STOPPING DISTANCES. SURVEYS CONDUCTED BY ODI AND VRTC INDICATE THAT ROUTING ANOMALIES MAY BE MORE COMMON THAN THE COMPLAINT AND WARRANTY DATA SUGGEST FOR THE SUBJECT LINE BUNDLE, WITH LINE CONTACT OR OTHER ROUTING ANOMALY NOTED IN 13 OF 51 VEHICLES SURVEYED BY ODI AND VRTC (25.5%).WHILE EVIDENCE OF CONTACT BETWEEN THE FUEL LINE AND SUBJECT BRAKE IN A PARTICULAR VEHICLE IS NOT NECESSARILY PREDICTIVE OF EVENTUAL LINE FAILURE/LEAKAGE, SIGNIFICANT CHAFING WEAR WAS NOTED IN TWO SURVEY VEHICLES (3.9%).TO ADDRESS CONCERNS WITH LINE ROUTING AND ENSURE THAT LINES WITH EVIDENT CHAFING DO NOT PROGRESS TO A LEAK CONDITION, MERCEDES WILL CONDUCT AN OWNER NOTIFICATION PROGRAM INSTRUCTING OWNERS TO BRING THE VEHICLES TO A DEALER FOR A FREE INSPECTION AND REPAIR.LINES THAT DO NOT HAVE A SPACER (RUBBER GROMMET OR OMEGA-CLIP) BETWEEN THE SUBJECT FUEL AND BRAKE LINES WILL HAVE AN OMEGA-CLIP SPACER INSTALLED TO ENSURE ADEQUATE CLEARANCE BETWEEN THE LINES.BRAKE LINES WITH CHAFE MARKS WILL BE REPLACED. ACCORDINGLY, THIS INVESTIGATION HAS BEEN CLOSED. THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST. THE AGENCY WILL CONTINUE TO MONITOR COMPLAINTS AND OTHER INFORMATION RELATING TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES AND TAKE FURTHER ACTION IN THE FUTURE IF WARRANTED. FOR ADDITIONAL INFORMATION REGARDING THIS ENGINEERING ANALYSIS REFER TO THE EA08-009 CLOSING REPORT.

MERCEDES-BENZ USA (MBUSA) WILL NOTIFY CERTAIN MODEL YEAR (MY) 1998 THROUGH 2003 M-CLASS OWNERS OF THE NEED TO BRING THEIR VEHICLES INTO DEALERS TO ADDRESS THE ISSUE PREVIOUSLY CAMPAIGNED UNDER MBUSA RECALL 2003-040005 (NHTSA RECALL 03V-121).THE MBUSA CAMPAIGN, WHICH ODI IS DESIGNATING RECALL 08V-465, WILL REPLACE THE POWER STEERING COOLER HOSE AND CLAMP IN ALL VEHICLES THAT RECEIVED THE ORIGINAL RECALL REMEDY FOR 03V-121 AND WHICH HAVEN'T RECEIVED A SUBSEQUENT REPAIR TO INSTALL A REVISED HOSE AND CLAMP.APPROXIMATELY ONE-THIRD OF THE VEHICLES THAT RECEIVED THE ORIGINAL REPAIR PROCEDURE AND PARTS RETURNED FOR SUBSEQUENT SERVICE FOR LEAKAGE FROM THE HOSE FITTING AND, IN APPROXIMATELY 10 PERCENT OF THESE VEHICLES, COMPLETE SEPARATION OF THE HOSE FROM THE COOLER.A REVISED SERVICE PROCEDURE FOR 03V-121, WHICH INVOLVED REPLACING THE OLD HOSE AND CLAMP WITH MODIFIED PARTS, HAD SIGNIFICANTLY LOWER RATES OF RETURN REPAIRS.MBUSA WILL APPLY THE REVISED SERVICE PROCEDURE FROM 03V-121 TO THE VEHICLES COVERED UNDER 08V-465.ACCORDINGLY THIS RECALL QUERY IS CLOSED.

THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED THIS PRELIMINARY EVALUATION TO INVESTIGATE ALLEGATIONS OF ENGINE CRANKSHAFT PULLEY HARMONIC BALANCER FAILURE THAT COULD RESULT IN LOSS OF POWER-STEERING ASSIST.ODI HAS RECEIVED A TOTAL OF 546 NON-DUPLICATIVE REPORTS THAT ALLEGE ENGINE CRANKSHAFT PULLEY HARMONIC BALANCER FAILURE ON ALL MERCEDES-BENZ VEHICLES USING THE SUBJECT COMPONENT.THE SUBJECT COMPONENT FAILURES ARE PROGRESSIVE IN NATURE AND ONLY A SMALL PERCENTAGE OF THE COMPLAINTS AND WARRANT CLAIMS INVOLVED A FAILURE THAT HAD PROGRESSED FAR ENOUGH TO EFFECT POWER STEERING PERFORMANCE (6 OF 55 ODI COMPLAINTS REFERENCE INCREASED STEERING EFFORT).THERE HAVE BEEN NO CRASHES OR INJURIES RELATED TO THE ALLEGED DEFECT.A SAFETY-RELATED DEFECT HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.SEE SUMMARY REPORT ATTACHED FOR FURTHER DETAIL.

DRIVING ON TAPPAN ZEE BRIDGE NEAR NYC AND SLOWED DOWN TO APPROX 15 MPH FOR TOLL BOOTH AND TRIED TO ACCELERATE OUT OF THE TOLLS. THE VEHICLE WAS VERY LOUD AND WOULD NOT ACCELERATE. IT ALMOST SOUNDED LIKE I WAS DRIVING OVER RUMBLE STRIPS AND I ALMOST CRASHED TRYING TO PULL OVER AS THE EZ-PASS IS ALL THE WAY ON THE LEFT SIDE OF THE FREEWAY. AFTER I GOT OUT THE FRONT PASSENGER ROTOR/CALIPER WAS ALMOST GLOWING AND ERUPTING WITH SMOKE, THE 3 OTHER BRAKES LOOKED FINE. THE SMOKE DID NOT STOP FOR AT LEAST 10-15 MINUTES AND IT SMELLED ABSOLUTELY TERRIBLE EVEN STANDING 15 FEET AWAY FROM THE VEHICLE. THE VEHICLE HAD TO BE FLAT-BEDDED TO THE DEALERSHIP AND THEY WHERE NOT ABLE TO DIAGNOSE THE ISSUE, THEY SAID IT SEEMED LIKE AN ELECTRICAL PROBLEM. AFTER BRINGING IT TO ANOTHER SHOP THEY SAID IT WAS A FAULTY YAW RATE SENSOR. *TR

NHTSA ID

10424020

Incident

Aug 20, 2011

Mileage

100,100 mi

NHTSA CAMPAIGN 99V328000. SEAT BELT BUCKLE RECALL. SEAT BELT BUCKLE EVEN AFTER THE RECALL INSPECTION AND REPLACEMENT IS DEFECTIVE, THE CONNECTION IN BETWEEN METAL SPRING AND PLASTIC IS UNSAFE AND UNSAFE, IT IS MADE OUT OF CHEAP PLASTIC, EVENTUALLY PLASTIC WILL FAIL AND SEAT BELT WILL UNLATCH. IT WILL CAUSE SERIOUS INJURIES IN A CRASH OR HARD STOP, MERCEDES IS NOT OFFERING ANY WARRANTY OR REPLACEMENT I WAS KICKED OUT OF THE DEALER WHEN I COMPLAINED, THEY SAID THEY WILL CALL THE POLICE ON ME. *TR

NHTSA ID

10373917

Incident

Dec 29, 2010

Mileage

120,000 mi

MY 1999 MERCEDES ML320 STALLED IN TRAFFIC ON THE INTERSTATE. I HAD IT TOWED TO THE DEALER WHO REPLACED THE CRANKSHAFT POSITION SENSOR WHICH SHOWED A MARGINAL PROBLEM. WE PICKED UP THE CAR AND BROUGHT TO THE ATTENTION OF THE MANAGER THAT THE "CHECK ENGINE" WAS ILLUMINATED. HE SAID THAT WAS BECAUSE THERE WERE SOME PLUGS MISFIRING, BUT THAT WOULD HAVE NO BEARING ON THE CAR STALLING. THE NEXT DAY, THE CAR STALLED IN TRAFFIC AND WAS AGAIN TOWED TO THE DEALER. THEY CAN FIND NOTHING WRONG WITH THE CAR AND SAY IT RUNS LIKE A TOP. WE REFUSED TO TAKE THE CAR UNTIL THE PROBLEM WAS RESOLVED SO IT WAS DECIDED THAT A TECHNICIAN WOULD DRIVE THE CAR UNTIL IT STALLED AGAIN. THAT HAS BEEN GOING ON FOR ONE WEEK WITH NO STALLING. WE ARE AT A LOSS AS TO HOW TO PROCEDE WITH THIS ISSUE. WE DO NOT FEEL IT IS SAFE TO DRIVE THE CAR BECAUSE WE FEAR IT WILL STOP AGAIN IN TRAFFIC AND CAUSE AN ACCIDENT AND/OR DEATHS. *TR

NHTSA ID

10360111

Incident

Sep 5, 2010

Mileage

70,650 mi

TIRE ALMOST NO TREAD AFTER 31,000 MILES WARRANTY FOR 65,000 MILES. *TR

NHTSA ID

10310206

Incident

Feb 2, 2010

Mileage

98,000 mi

WHEN TRYING TO TURN MY VEHICLE FROM A PARKING LOT, THERE WAS A SUDDEN LEAKAGE OF POWER STEERING FLUID AND THE STEERING WHEEL BECAME SO HARD TO TURN. THE CAR WAS NOT IN DRIVABLE CONDITION AND I TOWED IT TO MY NEAREST SERVICE STATION. AFTER DIAGNOSIS, POWER STEERING HOSE AND CLAMP WERE REPLACED AND THE CAR IS RUNNING GOOD NOW. LATER I FOUND THAT THIS IS A KNOWN ISSUE IN 1999 MERCEDES ML 320 AND FOUND RECALL CAMPAIGN DETAILS OF THIS ISSUE IN NHTSA WEBSITE. BUT WHEN I CALLED MERCEDES USA TO GET A REIMBURSEMENT FOR THE REPAIR COST, THEY ARE REFUSING TO GIVE REIMBURSEMENT FOR A STRANGE REASON. I AM STILL FOLLOWING THIS ISSUE WITH THEM. *TR

NHTSA ID

10292555

Incident

Oct 7, 2009

Mileage

117,000 mi

1999 ML 320 BEGAN JERKING ON MEDIUM GRADES. JERKING WAS REPORTED TO KNOXVILLE TN. MERCEDES BENZ DEALERSHIP. THEY REPORTED THE TRANSFER CASE IS FAILING. THEY INDICATED THAT TO THEIR KNOWLEDGE THERE HAS NEVER BEEN A TRANSFER CASE FAILURE ON AN ML 320. I HAD THE TRANSFER CASE REPLACED AT A COST OF $4300.00. *TR

NHTSA ID

10277218

Incident

May 6, 2009

Mileage

221,000 mi

MY CAR STOPPED STEERING. I COULD NOT TURN THE STEERING WHEEL. IT OCCURRED ON SATURDAY, DECEMBER 13,2008. I HAD MY CAR TOWED TO A MEINEKE SHOP. THEY DISCOVERED THAT MY HOSE AND CLAMP HAD TO BE REPLACED. I WENT TO MY CLOSEST MERECEDES BENZ SERVICE CENTER IN GREENWICH, CT THE NEXT WEEK. THEY COMPLETED THE REPAIR. I SUBMITTED MY MEINEKE BILL OF $50.35 FOR REIMBURSEMENT TO MY SALESMAN, PHIL BOUTALL. I WAS TOLD THAT I WOULD GET THE REFUND IN A FEW DAYS. IT HAS NOW BEEN OVER 3 MONTHS. I HAVE MADE NUMEROUS CALLS TO MR BOUTALL AND SPOKE TO HIM PERSONALLY AS WELL AS LEFT MESSAGES. BESIDES EMPTY PROMISES AND UNRETURNED VOICE MAILS I HAVE NOT RECEIVED MY REIMBURSEMENT. *TR

NHTSA ID

10261954

Incident

Dec 13, 2008

TL*THE CONTACT OWNS A 1999 MERCEDES BENZ ML320. WHILE DRIVING APPROXIMATELY 40 MPH ON NORMAL ROAD CONDITIONS, THE POWER STEERING FAILED WITHOUT WARNING. IMMEDIATELY, THE DRIVER EXERTED MORE EFFORT TO TURN THE STEERING WHEEL. THERE WAS ALSO EXCESSIVE POWER STEERING FLUID LEAKING. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER FOR INSPECTION AND THEY DISCOVERED NHTSA CAMPAIGN ID NUMBER 03V121000 (STEERING;HYDRAULIC POWER ASSIST;HOSE, PIPING, AND CONNECTIONS). THE VEHICLE WAS REPAIRED FOR THE RECALL. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER ON TWO SEPARATE OCCASIONS FOR IDENTICAL FAILURES, BUT THERE WERE NO RESOLUTIONS. THE VEHICLE IS IN THE PROCESS OF BEING TAKEN TO AN INDEPENDENT MECHANIC FOR A SECOND OPINION. THE FAILURE MILEAGE WAS 120,000 AND CURRENT MILEAGE WAS 127,000.

NHTSA ID

10255736

Incident

Dec 8, 2007

Mileage

120,000 mi

MERCEDES: SEE DOCUMENT SEARCH BUTTON FOR OWNER LETTER. THE LOWER POWER STEERING HOSE AND CLAMP SHOULD BE REPLACE, UNDER EXTENDED WARRANTY, DUE TO POWER STEERING LEAKAGE FROM CONNECTION TO POWER STEERING COOLER. MODELS 1998-2003 163.154, (ML320, 430, 55, 500, 350). *PE

ESP LAMP ILLUMINATED. *TT

SOME CUSTOMERS MAY COMPLAIN OF POOR AM / ELECTRICAL INTERFERENCE ON AM. *TT

SUBJECT REGARDING SRS CONTROL UNIT PROGRAMMING. *TT

CONDITIONS REGARDING THE TELEPHONE PRE-WIRING FROM THE RADIO COMPARTMENT TO THE CENTER CONSOLE WAS NOT INSTALLED BY THE FACTORY ON TELEPHONE KIT. *YC