2001 Mercedes-Benz M Class

ODI opened the investigation based on reports that the subject vehicle brake lamp switch (switch) failure caused 1) inoperative brake lamps (stay on or fail to illuminate), and/or 2) shift interlock failure (shifter locked in park), and/or 3) the cruise control to fail to cancel with brake application.Consumers also reported the illumination of a warning lamp on the instrument panel.The switch contains three sets of electrical contacts and a (normally extended) spring loaded plunger that actuates the contacts as it moves.As installed in the vehicle, the plunger contacts the brake pedal arm and is pushed into the switch; as the driver applies the pedal the plunger extends.One set of contacts (BLS) operates the stop lamps, a second set (EWM) controls the shift interlock system, and a third set (BS) is used by an on-board diagnostic (OBD) system to monitor switch operation.The cruise control monitors the BLS signal to determine when the brake is applied, the primary way the system is disabled when set.The relative timing of contact actuation in response to plunger movement allows the OBD system to detect a switch fault.When a fault is detected a malfunction indication lamp (MIL) is illuminated (driver alert), a diagnostic trouble code (DTC) is stored (for the service technician), and cruise control operation is inhibited (as a failsafe).In its response to ODI's January 2011 information request letter, MB explained its assessment of switch failures which was based primarily on evaluation of field return failures.MB identified both 1) electrical contact and 2) mechanical switch failure mechanisms.According to MB's analysis, electrical contact failure is the predominate failure type and the failure consequence depends on which contact fails.For instance MB claims that BLS contact failures are momentary in nature and do not affect brake light operation but are nonetheless detected by the OBD system, resulting in a DTC and subsequent replacement.Electrical contact failures of the BS and EWM contacts result in a DTC also, and EWM contact failures result in the shifter being stuck in the park (which can be overridden by the consumer).Accordingly MB maintains that electrical contact failures of the switch have no safety consequence since the brake lamps remain operational and the cruise control is always disabled.MB determined that mechanical failures of the switch, which are rare in their assessment, can result from internal wear and/or increased switch operating temperatures.High temperatures occur due to overheating of the BLS contacts and can cause the internal plastic components to melt.In one scenario overheated BLS contacts may melt to the extended plunger and are damaged when the brake pedal is released resulting in the brake lights staying on.In another scenario the increased temperatures and/or internal wear can cause the plunger to stick in the fully depressed position.In this case the cruise may not cancel when the brake is applied and the driver may have to use high brake pedal forces or other means (shifting to neutral or using the cruise master switch) to disengage the cruise.Additionally the vacuum assist can be depleted if the driver pumps the brakes resulting in reduced braking effectiveness and even higher pedal forces.In its March 31, 2011 defect notification, MB stated that to remediate the potential need for excessive brake force it would conduct a safety recall (11V-208) to replace the switch with a more robustly designed component.The recall includes 136,751 model year 2000 - 2002 M-Class and model year 2000 - 2004 M-Class AMG vehicles.Owner notification letters will be mailed

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.

ODI OPENED PE07-007 AFTER RECEIVING 4 COMPLAINTS WITHIN A 6 WEEK PERIOD ALLEGING INCIDENTS OF UNCOMMANDED BRAKE APPLICATION IN MODEL YEAR (MY) 2000 THROUGH 2001 MERCEDES M CLASS SPORT UTILITY VEHICLES.INFORMATION CONTAINED IN THE REPORTS OR GATHERED IN SUBSEQUENT CONSUMER INTERVIEWS INDICATED THAT THE INCIDENTS WERE CAUSED BY FAULTS IN THE ELECTRONIC STABILITY PROGRAM (ESP) SYSTEM WHICH WERE REPAIRED BY REPLACING THE YAW RATE SENSORS.ALTHOUGH THE SAME YAW RATE SENSOR IS USED IN APPROXIMATELY 800,000 OTHER MERCEDES M-CLASS, C-CLASS AND SLK MODELS, TO DATE THERE HAS BEEN ONLY ONE RELATED COMPLAINT TO ODI IN THOSE VEHICLES. DURING THIS INVESTIGATION MERCEDES BENZ PROVIDED ODI WITH 327 COMPLAINTS RELATED TO THE ESP SYSTEM IN THE MY 2000 THROUGH 2001 M CLASS VEHICLES.SEVEN OF THE COMPLAINTS SUBMITTED BY MERCEDES ALLEGED INCIDENTS OF UNCOMMANDED BRAKE ACTIVATION WHILE DRIVING, WITH TWO OF THESE INVOLVING VEHICLES IDENTIFIED IN THE ODI COMPLAINTS.NONE OF THE INCIDENTS RESULTED IN CRASH OR INJURY.HOWEVER, THE OWNERS DID EXPRESS SAFETY CONCERNS DUE TO THE SUDDEN, UNEXPECTED CHANGE IN VEHICLE SPEED AND DIRECTION. ON MAY 10, 2007 MERCEDES BENZ MET WITH NHTSA TO PROVIDE A TECHNICAL PRESENTATION AND CONDUCT A DRIVING DEMONSTRATION OF THE ESP SYSTEM PERFORMANCE WITH SIMULATED ELECTRICAL FAULTS IN THE YAW RATE SENSOR.MERCEDES SHOWED THAT THE ESP SYSTEM IS PROGRAMMED TO DIAGNOSE ELECTRICAL FAULTS AND THAT BRAKE APPLICATIONS RESULTING FROM YAW RATE SENSOR ELECTRICAL FAULTS ARE VERY SHORT IN DURATION (0.3 SECONDS OR LESS) AND DO NOT AFFECT VEHICLE CONTROL OR STABILITY. NINE OF THE CONSUMER COMPLAINTS TO ODI AND MERCEDES ALLEGED BRAKE ACTIVATIONS LONGER THAN 0.3 SECONDS, WITH SEVERAL ALLEGING THAT THE INCIDENT LASTED UNTIL THE VEHICLE CAME TO A STOP.A COMPLAINT VEHICLE THAT ALLEGED MULTIPLE INCIDENTS WAS EVALUATED BY ODI AT THE VEHICLE RESEARCH AND TEST CENTER (VRTC) IN EAST LIBERTY, OHIO.VRTC WAS UNABLE TO DUPLICATE THE CONDITION.DUE TO THE LOW COMPLAINT RATE AND ONLY ONE NEW COMPLAINT TO ODI OR MERCEDES SINCE JANUARY 2007, THIS INVESTIGATION HAS BEEN CLOSED.ODI WILL CONTINUE TO MONITOR COMPLAINTS IN THE SUBJECT VEHICLES AND OTHER MERCEDES PRODUCTS USING THE SAME YAW RATE SENSOR AND MERCEDES WILL PROVIDE UPDATES ON FIELD EXPERIENCE (COMPLAINTS, FIELD REPORTS AND WARRANTY CLAIMS) THROUGH THE END OF 2007.

TL*THE CONTACT OWNS A 2001 MERCEDES BENZ ML350. THE STEERING WHEEL WAS REPAIRED IN 2003 ACCORDING TO NHTSA CAMPAIGN ID NUMBER 08V465000 (STEERING: HYDRAULIC POWER ASSIST: HOSE, PIPING, AND CONNECTIONS); HOWEVER, THE STEERING WAS NEVER CORRECTED PROPERLY. THE STEERING MAKES A LOUD NOISE WHEN THE STEERING WHEEL IS TURNED. THE CONTACT RECENTLY RECEIVED A SECOND RECALL NOTICE AND SHE WILL TAKE THE VEHICLE TO THE DEALER. THE FAILURE MILEAGE WAS 60,000 AND CURRENT MILEAGE WAS 90,642.

NHTSA ID

10256074

Incident

Jan 1, 2003

Mileage

60,000 mi

I WAS HIT ON THE PASSENGER DOOR SIDE ON 8/6/05 BY A CAR RUNNING A RED LIGHT. MY CAR WAS HIT SO HARD IT ROLLED OVER RESTING ON IT'S ROOF. NO AIR BAGS DEPLOYED, NOT EVEN SIDE ONES. I CALLED MB-USA TO COMPLAIN. THEY DIDN'T SEEM CONCERNED ABOUT THE EVENT. *NM

NHTSA ID

10142648

Incident

Aug 6, 2005

SINCE THE CAR WAS PURCHASED IT CONTINUES TO HESITATE AND STALL OUT GIVING A "START ERROR" ON THE INSTRUMENT PANEL. HAD CONFIRMED BY THE SERVICE MANAGER, GERRY GRIFFITH (CAR PURCHASED IN INDIANAPOLIS, RECENT MOVE TO ALABAMA), THAT THE MODEL M-CLASS HAS PROBLEMS WITH THIS ISSUE. JUST HAD TO SPEND $1000+ ON A "FIX" AND THE PROBLEM HAS BEEN ONGOING SINCE THE BEGINNING OF PURCHASING THE CAR. DETAILED SERVICE RECORDS ARE NOT GIVEN TO THE CUSTOMER ONLY A BRIEF SYNOPSIS AND ALL WORK IS NOT INCLUDED IN THAT REPORT, I.E., THE ACTUAL TESTING CODES, ETC. *JB

NHTSA ID

10135790

Incident

Feb 20, 2001

Mileage

100 mi

JUST AS REPORTED IN CONSUMER REPORTS, ELECTRICAL SYSTEMS FAILED ON THIS VEHICLE CAUSING ALL SAFETY SYSTEMS (IE., BRAKE ASSIST, SAFETY BELTS, AIR BAGS) TO FAIL. THE PROBLEM CAUSED TWO ACCIDENTS LAST YEAR WHEN THE 4,400 LB. VEHICLE COULD NOT STOP. OTHER ELECTRICAL SYSTEMS ARE ALSO FAILING. FURTHER, THE REAR GATE LATCH WAS NOT LOCKING AND THE DEALER NEVER VERBALLY TOLD US WHEN WE PICKED UP THE VEHICLE FROM BEING SERVICED, NOR DID THEY EVER ASK IF WE WANTED IT FIXED. WE JUST FOUND OUT ABOUT THIS. ONE WOULD EXPECT MORE FROM A MERCEDES PRODUCT. AFTER THE TRUCK WAS "FIXED" TWICE, WE THEN PAID TO HAVE IT GONE OVER ($300) AND FOUND THE PROBLEM WITH THE SAFETY SYSTEMS WHICH HAD BEEN NOTED AS BEING FIXED PREVIOUSLY. IT WAS A $100 STOP SWITCH. MEANWHILE, WE WILL PAY HIGHER INSURANCE RATES FOR THE NEXT THREE YEARS. MERCEDES USA SHOULD HAVE RECALLED THESE VEHICLES FOR THE ELECTRICAL PROBLEMS, BUT THEY JUST BRUSHED IT UNDER THE RUG. I THOUGHT WE WERE BUYING A QUALITY PRODUCT. I GUESS NOT.*JB

NHTSA ID

10131784

Incident

Feb 28, 2005

Mileage

86,000 mi

I PURCHASED THIS VEHICLE IN MAY OF THIS YEAR AND EVERY MONTH I HAVE BEEN AT THE SERVICE DEPARTMENT TURNING IT IN FOR ONE PROBLEM OR ANOTHER. I AM ASSURED THEY ARE DOING ALL THAT THEY CAN BUT I HAVE NOT GONE 30 DAYS IN A ROW WITH A FUNCTIONING, NO PROBLEM, VEHICLE. I PURCHASED A MB BECAUSE I THOUGHT THE VALUE AND DEPENDABILITY WAS THERE. I THOUGHT THE VEHICLE WOULD BE HASSLE FREE AND I COULD ENJOY FEW MECHANICAL ISSUES. I AM NOT SPENDING TIME AWAY FROM WORK WHICH IS CAUSING ME PROBLEMS, JUST TO KEEP THIS SUV MAINTAINED. THE DEFECTS OR ISSUES WITH THIS VEHICLE ARE BECOMING AN ADDED EXPENSE TO ME AND THE TIME AWAY FROM WORK IS CAUSING ME PROBLEMS. I WANT A VEHICLE THAT IS NOT IN THE SHOP ONCE A MONTH. I TRIED TO CALL THE MERCEDES BENZ CUSTOMER SERVICE LINE AND THEY REFERRED ME BACK TO THE DEALER. THE DEALER HAS DONE NOTHING ABOVE AND BEYOND THEIR JOB RESPONSIBILITES. I AM NO DIFFERENT THAN THE CUSTOMER THAT COMES IN ONCE EVERY YEAR FOR REGULAR MAINTENANCE. I WOULD THINK THAT I WOULD BE TREATED A LITTLE DIFFERERNTLY AND THAT SOMEONE WOULD WANT TO SOLVE THIS PROBLEM! MY HUSBAND WANTED TO TRADE HIS BMW IN FOR A NEW MB BUT NOW I THINK HE HAS LOST FAITH THAT MB IS A RELIABLE, STABLE VEHICLE.

NHTSA ID

10070943

Incident

Sep 15, 2003

Mileage

30,000 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

ENGINE WILL NOT START AND FAULT MESSAGE START ERROR APPEARS IN INSTRUMENT CLUSTER. *TT

AIR MASS SENSOR REPLACEMENT DUE TO CHECK ENGINE LIGHT COMING ON AND CODES P2004, P0170 AND P0173. *TT *MJ

SOME VEHICLES MAY EXPERIENCE POOR NAVIGATION POSITIONING IN HIGHER ALTITUDES (VEHICLES DRIFTS OFF OF ROADS ON MAP SCREEN OR POOR RE-ROUTE CALCULATION). *TT

INFORMATION ON THE M6 SPORT PACKAGE OPTION. *TT