2007 Mercedes-Benz ML500

THIS PRELIMINARY EVALUATION INVESTIGATION CONCERNS THE SEAT BACK WARMER INSTALLED IN THE SUBJECT VEHICLES BUILT THROUGH MAY 2007, EQUIPPED WITH THE CTX' CARBOTEX SEAT WARMER DESIGN.THE DATA DISCLOSE FEW COMPLAINTS AND WARRANTY REPORTS CONCERNING THIS ISSUE.NONE OF THE FIRE REPORTS INVOLVED OPEN FLAME, BUT WERE THERMAL INCIDENTS IN WHICH THE SEAT CUSHION SUSTAINED DISCOLORATION OR A HOLE BURNED IN THE SEAT COVER.THE REPORTED INJURY APPEARED TO BE MINOR.THE SUBJECT SEAT WARMER DESIGN WAS ALSO INSTALLED IN MY 2006 M-CLASS VEHICLES AND THOSE DATA ALSO SHOW FEW INCIDENTS.A SAFETY DEFECT TREND HAS NOT BEEN IDENTIFIED.THIS INVESTIGATION HAS BEEN CLOSED.

2007 MERCEDES BENZ ML500. CONSUMER WRITES IN REGARD TO NHTSA SAFETY RECALL 22V-315. THE CONSUMER IS REQUESTING REIMBURSEMENT FOR A RENTAL CAR.

NHTSA ID

11510560

Incident

Mar 7, 2023

The contact owns a 2007 Mercedes Benz ML500. The contact stated that while her boyfriend was driving, the front and back seat warmers were operating and the driver noticed smoke. The contact mentioned there was a smoke odor and noticed the front driver seat caught on fire. The contact stated that the driver extinguished the fire with his clothes by smothering the seat. In addition, there was a hole in the seat. The vehicle was taken to the dealer where they failed to provide a diagnosis and informed the contact the seat was going to be unplugged. The vehicle was not repaired. The manufacturer was notified of the failure. The approximate failure mileage was 199,800.

NHTSA ID

11434025

Incident

Sep 10, 2021

Mileage

199,800 mi

I HAD MY HEATED SEAT ON THE MEDIUM SETTING. WHILE ON MY SHORT COMMUTE TO WORK (ABOUT 8 MINUTES) THIS MORNING MY DRIVER SEAT STARTED TO SMOKE AND BURNED A HOLE THROUGH THE LEATHER AND MELTED PART OF MY CLOTHING.

NHTSA ID

11156351

Incident

Dec 5, 2018

Mileage

155,000 mi

I GOT INTO MY CAR AND TURNED ON THE SEAT WARMER. AFTER 10 MINUTES OF DRIVING ON THE HIGHWAY I COULD SMELL SMOKE BUT THOUGHT IT WAS OUTSIDE THE VEHICLE. A FEW SECONDS LATER I FELT A BURNING SENSATION ON MY LOWER BACK. I REACHED MY LEFT HAND BEHIND ME TO CHECK AND FELT SOMETHING HOT, WHEN I PULLED MY HAND OUT MY FINGER TIPS WERE COVERED IN MELTED LEATHER. THE SMOKE BY THEN INCREASED, I SHUT THE SEAT WARMER OFF AND EXITED THE HIGHWAY AS QUICKLY AS POSSIBLE.

NHTSA ID

10958297

Incident

Dec 8, 2016

Mileage

123,000 mi

I WAS INFORMED THAT MY CAR HAD A RECALL IN FEBRUARY AND THE LOCAL MERCEDES-BENZ DEALERSHIP HAS JUST GAVE ME THE RUN AROUND ABOUT GETTING A WELDER TO COME DO THE JOB. THEY HAVE NOT GOT BACK TO ME ABOUT GETTING A WELDER TO COME AND I FEEL LIKE IF IT'S A SAFETY RECALL THAT THEY SHOULD GET ON THE BALL TO GET THE VEHICLE UP TO CALL. THEY DIDN'T GIVE ME THE RUNAROUND WHEN THEY TOOK MY MONEY FOR REPAIRS THEY DID TO MY CAR.

NHTSA ID

10918644

Incident

Mar 6, 2016

MECHANICAL FAILURE, STEERING JAM AND BRAKE DID NOT WORK DURING DRIVING AT 15-20 MPH IN SUBDIVISION STREET. GOT IN ACCIDENT HITTING THE VAN.

NHTSA ID

10909481

Incident

Sep 24, 2016

Mileage

59,175 mi

ON NOVEMBER 22, 2015 I TURNED ON MY HEATED SEAT AS I WAS EXITING A SHOPPING MALL PARKING LOT. WHEN I GOT ON THE MAJOR CITY STREET I WAS DRIVING ABOUT 35 MPH WHEN I FELT SOMETHING REALLY HOT ON MY BACK SO I JUMPED IN MY SEAT AND READJUSTED MY TOP, I FELT THE HEAT ON MY BACK AGAIN AND THIS TIME IT WAS HOTTER. I CAME TO A STOPLIGHT AND TURNED AROUND TO LOOK AT THE SEAT AND COULD SEE FIRE BURNING A HOLE THRU THE SEAT. I IMMEDIATELY STARTED PATTING THE SEAT TO STOP THE FIRE FROM SPREADING AND THEN TURNED OFF THE HEATED SEAT CONTROL. I CALLED THE MERCEDES BENZ DEALERSHIP AND ASKED IF THEY HAD A RECALL ON THE SEATS AND WAS ADVISED NO BUT THEY DID HAVE PROBLEMS WITH SOME. THEY ADVISED ME TO BRING THE VEHICLE IN AND THEY WOULD FIX AT NO COST TO ME. THEY REPLACED THE SEAT BACK.

NHTSA ID

10809201

Incident

Nov 22, 2015

Mileage

128,000 mi

I OWNED A 2007 MERCEDES ML500, THE REASON I DON'T OWN THE VEHICLE ANY LONGER IS BECAUSE IT BURNT UP IN MY PARKING LOT OUTSIDE OF MY OFFICE. THE EVENING BEFORE THE FIRE I HAD DINNER OUT AND WHEN I WENT TO UNLOCK MY CAR DOORS, THE RIGHT BLINKER LIGHT FLICKERED AND REMAINED ON. AS I GOT INTO THE CAR THE SOUND OF THE BLINKER WAS VERY QUICK AND I TURNED IT OFF BUT REALIZED THEN THAT IT WENT COMPLETELY OUT ALONG WITH THE RIGHT FRONT HEADLIGHT. THE NEXT MORNING I MADE AN APPOINTMENT T GET THOSE FIXED, IN THE MEANTIME I DROVE TO WORK AND PARKED. ONE OF MY CO-WORKERS WHOSE OFFICE FACES THE PARKING LOT SAID THAT THERE WAS SMOKE COMING OUT OF MY CAR. WE CALLED 911 RAN OUTSIDE AND WHEN WE OPENED THE DRIVERS DOOR THERE WERE FLAMES COMING OUT FROM UNDERNEATH THE PASSENGER SIDE SEAT. WE USED A FIRE EXTINGUISHER BUT THE FLAMES KEPT COMING BACK UNTIL THERE WAS A WHOOSH SOUND AND THE FIRE EXPLODED OUT OF THE CAR. AT THAT POINT WE ALL RAN FOR SAFETY AND HAD TO SIT AND WATCH WHILE MY CAR WAS ENGULFED IN FLAMES UNTIL THE FIRE DEPARTMENT COULD PUT IT OUT. THE ENTIRE INTERIOR OF THE VEHICLE WAS A BLACK CHARRED MESS FROM THE FRONT TO THE BACK, THE EXTERIOR WAS BURNT AND IT WAS A TOTAL LOSS. PRELIMINARY RESULTS ARE POINTING TO AN ELECTRICAL FAILURE IN THE SEAT. FYI - THE SEAT WARMER HAD NOT BEEN TURNED ON AT ALL, IN FACT, NO ONE HAS SAT IN THAT SEAT FOR WEEKS. *TR

NHTSA ID

10378769

Incident

Jan 6, 2011

Mileage

32,500 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 The sliding sunroof glass panel of the panoramic roof reverses during the closing process, either once or multiple times, without an entrapment (anti‑pinch) event being detected. The concern may occur temporarily or repeatedly during normal closing operation. Cause The automatic reversing function of the panoramic roof is overly sensitive due to parameterization in combination with seal counter‑pressure. This condition can cause the roof to reverse even though no obstruction is present. Remedy Retrofit the vehicle to meet Cleanpoint status “Panoramic sliding sunroof glass panel reverses during closing without a pinch event.” The retrofit includes: • Hardware modification (installation of a cover rail / EPDM lip) • Corresponding software update for the panoramic roof control unit The prescribed retrofit steps must be performed in the specified sequence as outlined in this document. 1) Retrofit the EPDM lip onto the rear edge of the panoramic sliding roof panel: • Clean the underside of the rear edge of the sliding sunroof panel (marking, Figure 1) (e.g., isopropanol). • Subsequently install the cover rail on the underside of the sliding sunroof panel (Figure 2). - Distance from the cover rail to the rear edge of the sliding sunroof panel A = 5 mm - Distance from the cover rail to the right and left edges of the sliding sunroof panel B = 9 mm - Apply firm pressure by hand along the entire bonding surface of the COVER RAIL - The wider flange at the ends of the cover rail (see Figure 3) must point in the direction of travel 2) Submit an XSS Ticket with the following requests to add SA code O75 to the Vehicle Data Card • Enter code "O75" (Oscar 75) in Vehicle Documentation System (Vedok): • Add the following AO text to KG 78: AO code O75 added as specified in LI77.21-P-075806 (Version 7). 3) Install new software from the panoramic roof control unit (TSSR296, A98, PSD) and teach in the anti-pinch protection again: • Connect XENTRY Diagnosis. - always use the current XENTRY Diagnosis software release with all available add-ons. - Strict compliance with the operation steps in XENTRY Diagnosis is absolutely essential! - Ensure adequate power supply to the vehicle's on-board electrical system battery (greater than 12.5 V) using a battery charger. • Commission the panoramic roof control unit - To do this, select "A98 – control module 'panoramic sliding sunroof' → adaptation → commissioning → Commission the control unit." - Then follow user guidance in XENTRY Diagnosis. • Disconnect XENTRY Diagnosis.

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 Headlamps leaking or fogged Cause The fogging of the headlamp is a natural phenomenon which can occur under certain climatic conditions. In contrast to a leaky headlamp, physical fogging does not result in a technical impairment of the headlamp. A leak test must be performed to determine if physical fogging exists or if the headlamp is leaky. Remedy In advance, observe LI82.10-P-078301 "Headlamp/front fog lamp leaky or fogged". 1. Prepare headlamp/check for external damage: For headlamps with a closed system • Check the headlamps for any external damage and check also for correct seating of the Gore-diaphragm/correct latching of the cover caps. • If the headlamp exhibits any external damage, replace the headlamp. For headlamps with an open system • Check the headlamps for any external damage and seal off the vent then make sure the cover caps are latched correctly into place. • If the headlamp exhibits any external damage, replace the headlamp. Note: A headlamp with external damage is not a warranty or goodwill case. 2. Leak test of headlamp with overpressure: Connect test adapter to pressure tester. (Figure 1) Check test adapter for leak tightness. To do so, connect plug and coupling (Figure 2) and apply a maximum overpressure of 30 mbar. • The pressure must remain constant. If the pressure does not remain constant, use a new adapter. Seal all the outlet openings using sealing compound and the given diaphragm with the plunger (Figure 3). (Figure 4) • Make allowance for the different headlamp variants here (there are different outlet openings). Check if the headlamp needs to be removed to gain access to the diagnostic socket on the headlamp housing. Plug the adapter onto the diagnostic socket on the headlamp housing. (Figure 5). Apply a maximum of 30 mbar overpressure to the headlamp housing. Note: If the maximum overpressure of 50 mbar is exceeded the headlamp seal will be damaged. • If a pressure drop of less than 10 mbar is measured within 30 seconds, the headlamp is tight and there is natural physical condensation• If a higher pressure drop than 10 mbar is measured within 30 seconds, the headlamp is leaky. Note: The leaky position can be localized with the aid of soap suds. Replace any leaky headlamps. Desiccant packs can be installed for headlamps that are not leaky. Observe the following documents for installation of desiccant packs: • LI82.10-P-078302 Fogged headlamp, desiccant pack installed - open ventilation system • LI82.10-P-078304 Fogged headlamp, desiccant pack installed - closed ventilation system

Complaint Headlamps leaking or fogged Cause The fogging of the headlamp is a natural phenomenon which can occur under certain climatic conditions. In contrast to a leaky headlamp, physical fogging does not result in a technical impairment of the headlamp. A leak test must be performed to determine if physical fogging exists or if the headlamp is leaky. Remedy Check for external damage: You can identify a damaged headlamp in the following way: For headlamps with a closed system 1. Check the headlamps for any external damage and check also for correct seating of the Gore-diaphragm/correct latching of the cover caps. 2. If the headlamp exhibits any external damage, replace the headlamp. For headlamps with an open system 1. Check the headlamps for any external damage and seal off the vent, then make sure the cover caps are latched correctly into place. 2. If the headlamp exhibits any external damage, replace the headlamp. Note: External damage to the headlamp does not present a warranty or goodwill case. 1. Clear fogged/condensed LED headlamps and LED rear lamps: 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 and connect battery support via a charger. 3. Open the hood or trunk. 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). 7. If the condensation has disappeared, nothing else has to be done. Note: If defrosting has been performed, you can skip the first step. 2. Leak test of headlamp with overpressure: • Connect test adapter to pressure tester. (Figure 1) • Check test adapter for leak tightness. To do so, connect plug and coupling (picture 2) and apply a maximum overpressure of 30 mbar. The pressure must remain constant. If the pressure does not remain constant, use a new adapter. • All vents have to be sealed with sealing compound and the existing diaphragm with the stamp (picture 3 [3]). (Picture 4) Make allowance for the different headlamp variants here (there are different outlet openings). • Check if the headlamp needs to be removed to gain access to the diagnostic socket on the headlamp housing. • Plug the adapter onto the diagnostic socket on the headlamp housing. (Picture 5). • Apply a maximum of 30 mbar overpressure to the headlamp housing. Note: If the maximum overpressure of 50 mbar is exceeded the headlamp seal will be damaged (picture 6). • If a pressure drop of less than 10 mbar is measured within 30 seconds, the headlamp is tight and there is natural physical condensation. • If a higher pressure drop than 10 mbar is measured within 30 seconds, the headlamp is leaky. Note: The leaky position can be localized with the aid of soap suds. If the pressure test is not passed, the headlamp is leaky. If the cause cannot be rectified, the headlamp must be replaced. Note: If the headlamp is replaced, no dry packs may be installed on the new replacement headlamp. AR82.10-P-5455WT was created for the pressure test. **NOTE - As of Sept 2025 the pressure testing tool is not finalized and may require modifications to fit properly. This AR can be used as a reference manual for all closed headlamps. In the event of an open headlamp system, the vent ducts must be sealed before the pressure test.