2003 Mercedes-Benz ML320

THIS INVESTIGATION WAS OPENED BASED ON THREE CONSUMER COMPLAINTS OF ELECTRIC SEAT WARMER OVERHEATING IN MY 2003 MERCEDES BENZ ML-320 VEHICLES.CONSUMERS ALLEGED THAT SUCH FAILURES MAY INFLICT BURN INJURIES TO SEAT OCCUPANTS.INVESTIGATION DISCLOSED THAT THE IDENTICAL SEAT WARMER DESIGN WAS INSTALLED IN 65.5 PERCENT OF ALL M-CLASS VEHICLES PRODUCED DURING MY 2000-2005.THE ALLEGED DEFECT RESULTED FROM BREAKAGE OF THE ELECTRICAL BUS WIRE OF THE HEATER GRID IN THE OUTBOARD SIDE OF THE SEAT BOLSTER.THE FAILURES WERE CAUSED BY REPEATED HIGH STRESS APPLIED DURING OCCUPANT INGRESS AND EGRESS.A SIMILAR FAILURE MODE HAD BEEN PREVIOUSLY IDENTIFIED IN INVESTIGATIONS OF THIS TYPE OF FAILURE IN OTHER VEHICLES.THE RATES OF COMPLAINTS AND WARRANTY CLAIMS FOR THE SUBJECT VEHICLES, AS WELL AS FOR OTHER M-CLASS VEHICLES WITH THE SAME SEAT WARMER DESIGN, WERE IN SOME CASES HIGHER, BUT ON THE SAME ORDER OF MAGNITUDE AS THE RATES SEEN IN OTHER VEHICLES INVESTIGATED.THE INFORMATION DISCLOSED THAT SEAT CUSHION DAMAGE WAS LIMITED TO SMALL, LOCALIZED AREAS AND THAT NO RISK OF FIRE EXISTED.THE INJURIES REPORTED WERE CONSISTENTLY VERY MINOR IN SEVERITY AND AT RATES COMPARABLE TO THOSE SEEN ON OTHER INVESTIGATIONS.ODI CONCLUDED THAT A SAFETY-RELATED DEFECT TREND WAS NOT IDENTIFIED IN THIS MATTER AT THIS TIME.ACCORDINGLY, THIS PE 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 RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.

LOSS OF POWER STEERING FLUID, IT APPEARS TO BE FROM THE HOSE CONNECTION TO THE RADIATOR DURING DRIVING AND WHILE STATIONERY. THIS ISSUE WAS PREVIOUSLY RECALLED, I BELIEVE TWICE. DEALER REQUESTED $125 DIAGNOSTIC CHARGE. MB USA INFORMED IN A PHONE CONVERSATION, THAT THIS PROBLEM WAS ALREADY FIXED OCTOBER 2008 UNDER RECALL, AND THE WARRANTY EXPIRED AND I SHOULD FIX ON MY OWN COST.

NHTSA ID

11060855

Incident

Jan 3, 2018

Mileage

79,500 mi

MY WIFE DROVE THE VEHICLE TO WORK ONE DAY AND WHEN SHE WAS PULLING OUT OF THE PARKING LOT ONTO A BUSY STREET, THE YELLOW TRIANGLE WITH EXCLAMATION POINT STARTED TO FLASH AND ENGAGED THE BRAKES. MY WIFE QUICKLY PULL OVER TO THE SIDE OF THE STREET AND MADE HER WAY BACK INTO THE PARKING LOT WHILE THE BRAKES WHERE ENGAGING. MY WIFE WAS UNABLE TO DRIVE THE VEHICLE HOME FROM WORK. WE LET THE VEHICLE SIT FOR SEVERAL MINUTES AND I WAS ABLE TO GET THE VEHICLE MOVING BUT THE BRAKES WERE ENGAGING AGAIN. I WAS ABLE TO GET THE VEHICLE BACK HOME. I HAVE TAKING THE VEHICLE TO SEVERAL SHOPS AND ALL THE SHOPS ARE SAYING THAT THERE IS AN ISSUE WITH THE TRACTION CONTROL SYSTEM. WHEN DRIVING THE VEHICLE FROM ONE OF THE SHOPS, AS SOON AS I PULLED OUT OF THE SHOP'S PARKING LOT THE BRAKES ENGAGED AND THE YELLOW TRIANGLE WITH EXCLAMATION WAS FLASHING. IT DID THIS FOR ABOUT 15 SECONDS CAUSED THE APPROACHING VEHICLE FROM THE REAR TO SLAM ON THEIR BRAKES TO AVOID REAR ENDING ME. THE VEHICLE HAS BECOME UNSAFE TO DRIVE BECAUSE WE JUST DON'T KNOW IF WHEN IT DOES THIS. IT HAPPENS RANDOMLY USUALLY AFTER THE VEHICLE AS BEEN SITTING OFF FOR A SEVERAL HOURS.

NHTSA ID

10936005

Incident

Nov 3, 2016

Mileage

187,000 mi

TL* THE CONTACT OWNS A 2003 MERCEDES-BENZ ML320. THE CONTACT STATED THAT THE VEHICLE ACCELERATED INDEPENDENTLY AND THE RPMS REVVED WITHOUT WARNING. THE VEHICLE WAS TAKEN TO A DEALER MULTIPLE TIMES, BUT THE FAILURE WAS UNABLE TO BE DIAGNOSED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS NOT AVAILABLE.

NHTSA ID

10874688

Incident

Feb 4, 2014

BAS LIGHT TURNS ON WHILE DRIVING ON THE FREEWAY AND THE CAR SHUTS OFF ON FREEWAY WHILE DRIVING. THE GAS PEDAL DIDN'T WORK SO I PULLED OVER. I FEEL LIKE ITS A DANGEROUS TO DRIVE AND PUTTING OTHER DRIVER IN DANGER SO I STOPPED DRIVING IT. THERE WAS A RECALL FOR 2000-2002 ML320 BUT MY CAR IS 2003 AND ITS DOING THE SAME ISSUES THAT THE 2000-2002 ML320

NHTSA ID

10838717

Incident

Jan 9, 2016

Mileage

160,000 mi

WHILE DRIVING, WENT OVER BUMP IN ROAD, AND TRUCK IMMEDIATELY LOST SPEED. PRESSURE ON GAS PEDAL WEAKEND. THERE WAS ABSOLUTELY NO ACCELERATION. I PULLED OVER AFTER ALMOST BEING HIT, AND TURNED VEHICLE OFF. RESTARTED AND PULL OVER INTO AUTOZONE TO HAVE THEM HOOK IT UP TO DIAGNOSTIC READER. IT CAME BACK WITH SEVERAL CODES, THAT ALL STATED "THROTTLE PEDAL POSITIONER MALFUNCTION" I HAVE BOUGHT AND REPLACED THIS ITEM 4 TIMES SINCE THIS INCIDENT, AND THE PROBLEM STILL EXISTS. I AM FORCED TO DRIVE THE VEHICLE BECAUSE I HAVE TO GET BACK AND FORTH TO WORK, BUT I'M ALWAYS VERY AFRAID THAT THIS PART IS GOING TO MALFUNCTION WHILE IN A BUSY INTERSECTION OR STREET, AND I ALONG WITH MY KIDS ARE GOING TO BE KILLED. IT HAPPENS AT LEAST TWO TO THREE TIME A WEEK, SOMETIMES MORE. *TR

NHTSA ID

10594921

Incident

Jul 4, 2013

Mileage

100,000 mi

TL* THE CONTACT OWNS A 2003 MERCEDES BENZ ML320. WHILE DRIVING APPROXIMATELY 40 MPH, THE BRAKES WERE ENGAGED NUMEROUS TIMES BEFORE THERE WAS A REDUCTION IN THE SPEED. THE CONTACT SMELLED AN UNUSUAL ODOR INSIDE OF THE VEHICLE. IN ADDITION, ON SEPARATE OCCASIONS A BURNING ODOR OF BRAKES EMITTED THROUGHOUT THE VEHICLE WHILE DRIVING. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHO WAS UNABLE TO DETECT A PROBLEM. THE MANUFACTURER WAS NOTIFIED OF THE PROBLEM. THE APPROXIMATE FAILURE MILEAGE WAS 30,000.

NHTSA ID

10450251

Incident

Jan 7, 2011

Mileage

30,000 mi

2003 ML 320 ROLLS BACK IN DRIVE. *TR

NHTSA ID

10351178

Incident

Apr 10, 2004

Mileage

25,000 mi

I HAD TAKEN MY MERCEDES ML320 IN FOR RECALL WORK #2003040005 AT MOTOR WORKS IN HOFFMAN ESTATES IL. FOR POWER STEERING PUMP RECALL AND THEY WANTED TO CHARGE ME APPROX. $6,000.00 FOR THIS SERVICE WHICH SHOULD BE FREE. I'VE TRIED TO CONTACT MERCEDES AND MOTOR WORKS WITH NO RESPONSE THE CLAMPS THAT CONNECT THE POWER STEERING HOSES COME OFF QUITE OFTEN RESULTING IN LOSS OF CONTROL, I GUESS I SHOULDN'T EXPECT MUCH FOR A $40,000.00 CAR!! *TR

NHTSA ID

10258537

Incident

Dec 20, 2008

Mileage

90,000 mi

Single throttle lift-off clunking noise from the side shaft when moving off (audible at the outboard end). The noise is heard once in each instance when changing direction of travel. Note: Sound file in attachment Cause If the complaint is eliminated by experimentally loosening the outboard collar nut (by 1 turn), the problem is due to cracking of the microweld between the wheel bearing inner race and the joint housing of the side shaft. Note: The collar nut must always be replaced after being loosened. See also LI33.20-P-078406 Remedy Coat contact surface of side shaft with wheel bearing with Molykote paint. To do this, proceed as follows: 1. Remove side shafts 2. Clean contact surface A (see image file in attachment "Outer joint housing before") before coating with Molykote, using "spirit" (free of dust and grease) 3. Coat contact surface A (see image file in attachment "Outer joint housing after") with Molykote and leave to dry for "one hour" in removed condition 4. Reinstall side shafts Note: Before using the antifriction coating (Molykote), stir it or shake it thoroughly for (at least 1 minute).

Complaint Headlamp, front fog lamp leaky or fogged. Cause Fogging of the headlamps is a natural phenomenon, which can occur under certain climatic conditions. It does not lead to any technical impairment of the headlamp. If a pressure compensation diaphragm is fitted in the housing cover, then the lamp unit is a "closed system". Remedy Headlamp: Remedy 1 Clearing fogged/condensed LED headlamps: 1. Drive vehicle into workshop (temperature higher than +18 °C/+64.4 °F) and connect the exhaust extraction. Note: Do not perform an engine wash before the defogging test. 2. Switch off the engine and connect battery support via a charger. 3. Open the hood. 4. Switch on the lights. 5. Leave the vehicle in this state for 60 minutes. 6. Check for formation of condensation, a significant reduction in the formation of condensation must be clearly recognizable (thawing progress). Clearing of fogged/condensed LED headlamps and LED rear lamps on electric vehicles: 1. Drive the vehicle into the workshop (temperature higher than +18 °C/+64.4°F). 2. Connect battery backup via a charger. 3. Open the front-end flap and ensure sufficient ventilation. 4. Switch on the lights. 5. Leave the vehicle in this state for 60 minutes. 6. Check for formation of condensation, a significant reduction in the formation of condensation must be clearly recognizable (thawing progress). Clearing fogged/condensed halogen/xenon headlamps: 1. Drive the vehicle into the workshop (temperature higher than +18 °C/+64.4°F). Note: Do not perform an engine wash before the defogging test. 2. Switch off the engine. 3. Open the hood. 4. Switch off the lights. 5. Leave the vehicle in this state for 60 minutes. 6. Check for formation of condensation, a significant reduction in the formation of condensation must be clearly recognizable (thawing progress). Note: If there is no visible reduction in condensation, check the headlamp for malfunctions. (see Remedy 2) It is not physically possible to defog the headlamps completely. Fogging does not impair the operation or the service life of the headlamp. Note: Only implement Remedy 1 for model series 463 (from model year 2018) and model series 465. Remedy 2 A defective headlamp can be identified as follows: 1. Check the headlamp for external damage and that the cover caps and the diaphragm are correctly seated. 2. Check the electrical connectors of the plugs and pins. 3. Check for leak tightness according to LI82.10-P-078307. The test can only be conducted on headlamps. 4. If the headlamp or the rear lamp has any external damage, replace the component part in accordance with the WIS instructions. Note: External damage to the headlamp/rear lamp or faulty seating of the cover caps does not present a warranty or goodwill case. Note: With headlamps, it is possible to install desiccant packs if the problem occurs repeatedly. • Open ventilation system LI82.10-P-078302 • Closed ventilation system LI82.10-P-078304

Complaint Headlamp, front fog lamp leaky or fogged Cause Fogging of the headlamps is a natural phenomenon, which can occur under certain climatic conditions. It does not lead to any technical impairment of the headlamp. If a pressure compensation diaphragm is fitted in the housing cover, then the lamp unit is a "closed system". Remedy Headlamp: Remedy 1 Clearing fogged/condensed LED headlamps: 1. Drive vehicle into workshop (temperature higher than +18 °C/+64.4 °F) and connect the exhaust extraction. Note: Do not perform an engine wash before the defogging test. 2. Switch off the engine and connect battery support via a charger. 3. Open the hood. 4. Switch on the lights. 5. Leave the vehicle in this state for 60 minutes. 6. Check for formation of condensation, a significant reduction in the formation of condensation must be clearly recognizable (thawing progress). Clearing of fogged/condensed LED headlamps and LED rear lamps on electric vehicles: 1. Drive the vehicle into the workshop (temperature higher than +18 °C/+64.4°F). 2. Connect battery backup via a charger. 3. Open the front-end flap and ensure sufficient ventilation. 4. Switch on the lights. 5. Leave the vehicle in this state for 60 minutes. 6. Check for formation of condensation, a significant reduction in the formation of condensation must be clearly recognizable (thawing progress). Clearing fogged/condensed halogen/xenon headlamps: 1. Drive the vehicle into the workshop (temperature higher than +18 °C/+64.4°F). Note: Do not perform an engine wash before the defogging test. 2. Switch off the engine. 3. Open the hood. 4. Switch off the lights. 5. Leave the vehicle in this state for 60 minutes. 6. Check for formation of condensation, a significant reduction in the formation of condensation must be clearly recognizable (thawing progress). Note: If there is no visible reduction in condensation, check the headlamp for malfunctions. (see Remedy 2) It is not physically possible to defog the headlamps completely. Fogging does not impair the operation or the service life of the headlamp. Note: Only implement Remedy 1 for model series 463 (from model year 2018) and model series 465. Remedy 2 A defective headlamp can be identified as follows: 1. Check the headlamp for external damage and that the cover caps and the diaphragm are correctly seated. 2. Check the electrical connectors of the plugs and pins. 3. Check for leak tightness according to LI82.10-P-078307. The test can only be conducted on headlamps. 4. If the headlamp or the rear lamp has any external damage, replace the component part in accordance with the WIS instructions. Note: External damage to the headlamp/rear lamp or faulty seating of the cover caps does not present a warranty or goodwill case. Note: With headlamps, it is possible to install desiccant packs if the problem occurs repeatedly. • Open ventilation system LI82.10-P-078302 • Closed ventilation system LI82.10-P-078304

Complaint Headlamp, front fog lamp leaky or fogged Cause Fogging of the headlamps is a natural phenomenon, which can occur under certain climatic conditions. It does not lead to any technical impairment of the headlamp. If a pressure compensation diaphragm is fitted in the housing cover, then the lamp unit is a "closed system". Remedy Headlamp: Remedy 1 Clearing fogged/condensed LED headlamps: 1. Drive vehicle into workshop (temperature higher than +18 °C/+64.4 °F) and connect the exhaust extraction. Note: Do not perform an engine wash before the defogging test. 2. Switch off the engine and connect battery support via a charger. 3. Open the hood. 4. Switch on the lights. 5. Leave the vehicle in this state for 60 minutes. 6. Check for formation of condensation, a significant reduction in the formation of condensation must be clearly recognizable (thawing progress). Clearing of fogged/condensed LED headlamps and LED rear lamps on electric vehicles: 1. Drive the vehicle into the workshop (temperature higher than +18 °C/+64.4°F). 2. Connect battery backup via a charger. 3. Open the front-end flap and ensure sufficient ventilation. 4. Switch on the lights. 5. Leave the vehicle in this state for 60 minutes. 6. Check for formation of condensation, a significant reduction in the formation of condensation must be clearly recognizable (thawing progress). Clearing fogged/condensed halogen/xenon headlamps: 1. Drive the vehicle into the workshop (temperature higher than +18 °C/+64.4°F). Note: Do not perform an engine wash before the defogging test. 2. Switch off the engine. 3. Open the hood. 4. Switch off the lights. 5. Leave the vehicle in this state for 60 minutes. 6. Check for formation of condensation, a significant reduction in the formation of condensation must be clearly recognizable (thawing progress). Note: If there is no visible reduction in condensation, check the headlamp for malfunctions. (see Remedy 2) It is not physically possible to defog the headlamps completely. Fogging does not impair the operation or the service life of the headlamp. Remedy 2 A defective headlamp can be identified as follows: 1. Check the headlamp for external damage and that the cover caps and the diaphragm are correctly seated. 2. Check the electrical connectors of the plugs and pins. 3. Check for leak tightness according to LI82.10-P-078307. The test can only be conducted on headlamps. 4. If the headlamp or the rear lamp has any external damage, replace the component part in accordance with the WIS instructions. Note: External damage to the headlamp/rear lamp or faulty seating of the cover caps does not present a warranty or goodwill case. Note: With headlamps, it is possible to install desiccant packs if the problem occurs repeatedly. • Open ventilation system LI82.10-P-078302 • Closed ventilation system LI82.10-P-078304

Complaint Single throttle lift-off clunking noise from the side shaft when moving off (audible at the outboard end). The clunk is heard once when changing from forward to reverse (and vice versa). Note: Sound file in attachment Cause If the complaint is eliminated by experimentally loosening the outboard collar nut (by 1 turn), the problem is due to micromovement in the connection between the wheel bearing inner race and the joint housing of the side shaft. Note: The collar nut must always be replaced after being loosened and must be tightened to the specified torque. Remedy Coat contact surface of side shaft with wheel bearing with Molykote paint. To do this, proceed as follows: 1. Remove outboard side shafts (extract outer joint gearing from wheel hub) 2. Clean contact surface A (see picture file in attachment "Outer joint housing before") before coating with Molykote, using "spirit" (free of dust and grease) 3. Coat contact surface A (see image file in attachment "Outer joint housing after") using Molykote and leave to dry for one hour in removed condition 4. Reinstall side shafts Note: Before using the antifriction coating (Molykote), stir or shake it well (for at least 1 minute).

Complaint Single throttle lift-off clunking noise from the side shaft when moving off (audible at the outboard end). The clunk is heard once when changing from forward to reverse (and vice versa). Note: Sound file in attachment Cause If the complaint is eliminated by experimentally loosening the outboard collar nut (by 1 turn), the problem is due to micromovement in the connection between the wheel bearing inner race and the joint housing of the side shaft. Note: The collar nut must always be replaced after being loosened and must be tightened to the specified torque. Remedy Coat contact surface of side shaft with wheel bearing with Molykote paint. To do this, proceed as follows: 1. Remove outboard side shafts (extract outer joint gearing from wheel hub) 2. Clean contact surface A (see image file in attachment "Outer joint housing before") before coating with Molykote, using "spirit" (free of dust and grease) 3. Coat contact surface A (see image file in attachment "Outer joint housing after") using Molykote and leave to dry for one hour in removed condition 4. Reinstall side shafts