2020 Mercedes-Benz Sprinter 2500

What component or system failed or malfunctioned, and is it available for inspection upon request? The Adaptive Cruise Control turns off and then won't reset while driving. When the Adaptive Cruise Control turns off and then won't reset while driving. How was your safety or the safety of others put at risk? This causes the vehicle to immediately loose power. When traveling at highway speeds and vehicles are getting ready to pass us, then the cruise stops, we have been nearly rear ended multiple times on our last trip. Has the problem been reproduced or confirmed by a dealer or independent service center? This has been inspected but the service center couldn’t reproduce because it happens after several hours of driving. We had this problem several times while traveling from Denver Colorado to Pittsburg Kansas. If we stopped for fuel or food, and turned the vehicle off it would be fine on restart. If we were driving when it turned off we would have to follow another vehicle at a constant distance for more than 5 minutes to get the system to reset. Sometimes it worked sometimes it didn't. This is also a safety issue because we were having to follow fairly close to a vehicle in front of us to get the system to reset. We also tried turning the system off every hour or so, use the “cancel” button while driving, but it didn’t seem to make a difference. The system continued to randomly turn itself off. Has the vehicle or component been inspected by the manufacturer, police, insurance representatives or others? We took the Sprinter in to a Mercedes-Benz dealer service center and they checked everything and said it was fine. Then we took it back a second time and asked if there was some sort of calibration or computer software update needed. They inspected the vehicle again and informed us everything was up to date. I do not feel that this issue was being taken seriously as it is very nerve racking when it happens and then trying to not get in an accident when traveling

NHTSA ID

11756609

Incident

Aug 6, 2026

Sudden complete engine failures occurred in my Mercedes-Benz Sprinter van during highway operation while transporting freight, creating a serious safety hazard due to immediate and total loss of engine power in active traffic conditions. The first engine failure occurred at approximately 303,000 miles. The second failure occurred at approximately 140,000 miles after engine replacement. In both cases, there were no prior warning signs, diagnostic alerts, abnormal noises, or performance issues before sudden and catastrophic engine shutdown. Both incidents occurred while I was operating the vehicle at highway speeds during commercial freight delivery. The engine failed without warning, resulting in immediate loss of propulsion while in traffic. On both occasions, I was forced to rapidly maneuver the disabled vehicle to the shoulder under reduced control and arrange emergency towing to safely remove the vehicle from the roadway and prevent a potential collision or injury. These failures created a significant highway safety risk due to the abrupt loss of power while merging, traveling in traffic flow, and operating at speed. A sudden engine shutdown in these conditions could result in a rear-end collision, loss of control, or multi-vehicle accident, particularly in high-speed or heavy traffic environments. The repeated nature of catastrophic engine failure following engine replacement raises concern about a potential underlying defect in the engine system, components, or related assemblies, or possible unresolved mechanical or installation-related issues. The recurrence of identical failure conditions under similar operating circumstances increases concern that this may not be an isolated incident. Vehicle Information: Mercedes-Benz Sprinter used for commercial freight delivery First engine failure: ~303,000 miles Second engine failure: ~140,000 miles (replacement engine) Failure type: Sudden, complete engine shutdown with no warning at highway speed

NHTSA ID

11737931

Incident

Apr 21, 2026

On November 28, 2025, I experienced a vehicle fire in my Mercedes 2020 Sprinter 2500 4WD van. The van engine was on and idling while heating up with the van heater blower on level 6 (out of 7). After about 45 minutes, I saw a haze first and then smelled smoke. Unsure of the source, I turned the vehicle off and exited with my dog. I opened the hood to look for smoke in the engine bay. No smoke under the hood. I contact Mercedes Roadside and open the driver side door where I see flames under the seat. I grabbed the fire extinguisher I installed and put the fire out within 20-25 seconds of seeing it. I believe the root cause of the fire was running the van blower at a high setting for a sustained 45 minutes. My dog and I were inside and definitely in danger. It scares me to think of a scenario where the van was idling with only my dog inside and something like this occurring. The incident is currently under investigation with MB USA and my insurance company, Progressive. No warning signs or dashboard messages. In general, the electrical wiring for my vehicle has been spotty and was completely rewired by the dealer service center in 2021. Currently, there is an issue blacking out the dashboard screen so there is no screen function including gps, entertainment, or vehicle info.

NHTSA ID

11703896

Incident

Nov 28, 2025

I had 5 recalls completed at the MB Sprinter dealership in Pleasanton CA on 11/06/2025. Had hardly driven it 100 miles or 5 times since then when I noticed it was not always going into park. One recall had to do with not going in park when you push park button while foot on brake. I was not having that problem until the MB Sprinter dealership did the recall work. Now every 5th time or so it does not go in park when I push park button while foot on brake. Dealership insists I must pay to have this fixed even though their recall work caused it. This is a severe safety hazard that could result in death!

NHTSA ID

11703605

Incident

Nov 7, 2025

I’ve had two issues with my sprinter van that were transmission shift module that left me stranded with no way to shift the car into neutral. I was blocking a fuel pump and couldn’t get the car into gear. The first time I was stuck in a parking lot with the same issue. I can’t believe no one else had this issue. The screen message said “Service required do not shift gears” I purchased the van new in 2020. It only has 17000 miles on it. The dealerships Mercedes Benz in Sioux Falls and Mercedes Benz in Rochester Minnesota repaired the van.

NHTSA ID

11686750

Incident

Jun 19, 2025

The contact owns a 2020 Mercedes-Benz Sprinter 2500. The contact stated that while in reverse, the rearview camera failed to display a rearview image. No warning lights were illuminated. The vehicle was taken to the dealer, who was unable to provide a cause for the failure. The vehicle was not repaired. After investigating the failure, the contact related the failure to NHTSA Campaign Number: 21V411000 (Electrical System, Back Over Prevention); but the VIN was not included in the recall. The manufacturer was notified of the failure and referred the contact to the NHTSA Hotline for assistance. The failure mileage was 51,000.

NHTSA ID

11682962

Incident

Aug 25, 2025

Mileage

51,000 mi

repeated EGR clogging and malfunction: bucking or stumbling behavior, inability to accelerate properly, disabled shifting affecting ability to slow or stop without excessive use of brakes, Limp Home Mode suddenly without warning including inability to maintain a safe speed on highway and speed minimums that the vehicle cannot keep up (20 mph max while climbing moderately), unable to downshift when going downhill - relying solely on braking to keep speed below safe limit or speed limits. EGR failed again after cleaning, in as little as 3 months. No repair seems possible, only repeated cleanings. Since this happened so much, we have been in several unsafe situations due to the sudden and unheralded degradation of performance and safe use of the vehicle. Once repaired, the condition can come back immediately due to the computer still guessing that it is still in failure (limp home mode returned suddenly without warning as we merged onto an interstate with no exit for 7 miles uphill… and only made 20mph). Check Engine light could come on, and did, but never during the actual degradation of performance - and went often after a few run cycles. Mercedes dealers have confirmed and performed all services on the EGR and related issues (malfunction once caused the aircleaner element to be sucked in and that caused a MAF to be destroyed by contaminants): 1) first signs of issue before 43,000 miles (when check engine light and/or LHM happened -repaired 18sep2023, 51,871 miles, MB service code: LI14.20-N-073867); 2) 26 DEC 2023 - EGR failure diagnosed and replaced by MB dealer. Cleaning had not fixed the issue or failure was final as found by driving by technician and not by codes! 3) 09/jul/2024 - MAF replaced, EGR codes noted - but functioning, fix by MB/Canada 4) 07/24/2024 - 70,547 miles - EGR Clean by MB Missoula MT - failed upon highway same day 5) 07/25/2025 - 70,600 miles - MB Missoula MT cleared computer 6) 88,340 MB cleaned EGR - runs ok again

NHTSA ID

11674336

Incident

Jul 24, 2024

While driving the vehicle, 4x4 and low range would engage on its own. It would cause the transfer case to grind, clunk, and lock up. This happened while the vehicle was in motion and could have easily sent the vehicle out of control. Some warning lights appeared on the dash. I took it into the dealership, they diagnosed it as a glitch in the transfer case actuator software. They updated the software and declined my warranty claim since the powertrain warranty did not cover software updates. I had to pay out of pocket for this fix. The issue is common to this model.

NHTSA ID

11654889

Incident

Mar 7, 2025

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.