2018 Mercedes-Benz Sprinter 3500

From 2000 through 2017, Takata produced millions of air bag inflators using two types of phase-stabilized ammonium nitrate ("PSAN") propellant -- propellant 2004 and propellant 2004L. After prolonged exposure to high temperature cycles and humidity, inflators using propellant 2004 can degrade, causing the propellant to burn too quickly when ignited. The rapid burning can cause the inflator to rupture during deployment, potentially causing serious or even fatal injury to vehicle occupants. See 2016 Blomquist Report at www.nhtsa.gov/sites/nhtsa.gov/files/documents/expert_report-hrblomquist.pdf.Consequently, all frontal inflators using propellant 2004 that do not contain a "desiccant" (a substance that traps and holds moisture) in US vehicles are under recall. These "non-desiccated" inflators either have been or are required to be replaced.In some cases, the remedy part for these recalled inflators was, or will be, an inflator using either propellant 2004 or 2004L that does contain a desiccant. None of these "desiccated" remedy parts (which were installed in older model year vehicles) are currently under recall for a degradation concern. Certain subsets of desiccated PSAN inflators using propellant 2004 for use as original equipment, however, have been recalled for a degradation concern. All Takata inflators produced with propellant 2004L contain desiccant, and none of these desiccated inflators using propellant 2004L are under recall for a degradation concern. There have been no reported field ruptures in any non-recalled desiccated PSAN inflators.It is understood that desiccants fully saturate at some threshold, at which point any additional moisture will not be captured. This means the degradation process observed in non-desiccated inflators using propellant 2004 may also occur in non-recalled desiccated inflators using propellant 2004, assuming additional moisture enters the inflator and high temperature cycling occurs. Based on available information, desiccant saturation can occur within the first five years in the worst environments, and the time required for full saturation is affected by multiple factors. While no present safety risk has been identified, further work is needed to evaluate the future risk of non-recalled desiccated inflators using propellant 2004.Three entities -- Takata (now known as TK Global), the Independent Testing Coalition, and Exponent -- have been studying the long-term behavior of Takata desiccated PSAN inflators using propellant 2004L (as well as 2004) in the presence of moisture and temperature cycling. The research efforts, which include development of predictive modeling techniques and field sample analysis, are ongoing. To date, none of the researchers have identified field evidence showing that propellant 2004L is undergoing a degradation process that leads to aggressive deployment and potential rupture. However, the time in service of such inflators remains short compared to that of the inflators using propellant 2004. Further study is needed to assess the long-term safety of desiccated inflators using propellant 2004L.The Office of Defects Investigation is opening this investigation to examine whether a safety defect related to propellant degradation exists in non-recalled desiccated PSAN frontal inflators manufactured by Takata. This investigation will require extensive information on Takata production processes and surveys of inflators in the field. Lists of recall actions that may have used desiccated PSAN inflators as remedy parts, as well as the makes and models originally manufactured with them, is available with the downloadable version of this document (see nhtsa.gov/recalls?nhtsaId=EA21002 -- note this information is subject to change/revision as the investigation proceeds). This investigation does not supersede EA15-001, which remains open.

The Office of Defects Investigation (ODI) analyzed complaint data provided by Daimler Vans USA, LLC (Daimler) as well as complaints submitted to ODI from consumers to identify incidents related to Rear Wheel Speed Sensors (RWSS) failures. ODI's analysis identified 6,710 incidents of RWSS failure (unique VINs) in MY 2012-2018 Mercedes- Benz and Freightliner Sprinter vehicles upfitted to campers or recreational vehicles (RVs) representing 81 percent of all Sprinter RWSS reports. Complaint and warranty analysis indicated that the majority of incidents (approximately 99%) were related to RWSS moisture intrusion condition in the Sprinter 3500 5-ton variant, which accounts for 98 percent of upfit campers, where moisture build-up and crystal dendrite formation develop in parked RVs and lead to sensor failures. According to the Daimler Information Request (IR) response, if the wheel speed information is detected as implausible by the Electronic Stability Program (ESP) control unit, the ESP system enters a failsafe mode where:-Driver torque requests are no longer accepted;-Cruise control, if used, would be deactivated; -The ESP/ABS system shuts off; and -Multiple warning lamps and messages advise the operator to take the vehicle to the workshop. While the majority of reports involved only ABS and/or ESP warning lights and messages on the instrument cluster due to faulty sensor signals triggering a failsafe mode, some reports cited intermittent sensor failures resulting in increased vehicle speed while in cruise control and degraded ABS or ESP. Degraded ESP functionality may impact driving stability of the 5-ton vehicle.On Feb 3, 2021, following discussion with ODI, Daimler submitted a Defect Information Report (DIR) to NHTSA describing a defect in the RWSS disabling the ESP control unit functions in approximately 48,667 MY 2012 through 2018 Mercedes-Benz and Freightliner Sprinter 3500 vehicles manufactured from Jan 4, 2012 through Oct 25, 2018 (Recall 21V-042). In its DIR, Daimler indicated that RWSS sensor failures are prevalent in camper vans due to sustained periods of non-use, during which time the moisture may not dry out, remaining inside the plastic housing package. If the moisture within the RWSS dries and the RWSS returns to normal operation, the failsafe mode and the warning lights will disappear at the next ignition cycle, but the sensor fault remains stored within the ESP control unit and can be accessed through a diagnostic evaluation. ODI will continue to monitor field experience in Sprinter non-RVs and Sprinter 2500 RVs 3-ton and 3.5-ton variants (approximately 626 vehicles).Daimler will notify owners of the recalled vehicles and advise them to take their vehicle to a Mercedes-Benz or Freightliner Sprinter dealer, who will replace the RWSS with a repackaged sensor with high robustness against moisture intrusion. Daimler began notifying dealers and owners in Feb 2021. This Preliminary Evaluation is closed.The ODI reports cited above can be reviewed at NHTSA.gov under the following ID numbers:11352380 11351299 11350521 11348969 11342776 11342464 11341988 11341151 11340388 11338230 11337921 11331832 11331829 11331476 11331427 11331066 11328671 11325768 11325693 11322814 11322346 11320295 11319376 11317336 11311647 11310621 11308318 11254223 11253828 11252220 11196530 11194330 11164250 11145019 11141273 11139000 11138785 11124129 11094122 11394837 11390889 11390039 11389262 11387883 11387713 11386418 11383887 11383866 11382947 11377384 11376615 11376973 11375781 11375403 11374997 11374151 11373892 11373111 11366293 11365920 11365594 11365355 11365194 11364253 11364346 11363990 11363787 11362948 113629

The contact owns a 2018 Mercedes Benz Sprinter 3500. The contact stated that while starting the vehicle, the contact noticed that the Diesel Exhaust Fluid (DEF) warning light was illuminated. The vehicle was taken to the dealer where it was diagnosed and determined that the Diesel Exhaust Fluid (DEF) tank had failed and needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure and referred the contact to the NHSTA Hotline for assistance. The approximate failure mileage was 15,000.

NHTSA ID

11642281

Incident

Feb 12, 2025

Mileage

15,000 mi

We have a 2019 motorhome on a 2018 Mercedes Sprinter chassis. We are concerned about the wheel speed sensor failing. Three out of 4 sensors have already failed and been replaced on ours and Mercedes will not replace the 4th sensor until it fails. When this sensor fails it affects the ABS brakes and the braking distance is increased which can cause an accident. The cruise control is also affected and could increase speed on its own. The ESP can also be affected and can increase the risk of skidding and accidents. We have spoken to many other motorhome owners with the same chassis and they have also had problems with the sensors. Mercedes is aware of this problem and we feel they should replace all the sensors before they fail and cause a serious accident and injury or death. We would like to travel to remote areas of our country but haven't done so because there is no place to get the sensor replaced if it fails. We have spoken to Mercedes Benz of Sarasota FL and Mercedes Corporate and they are unwilling to do anything to replace the 4th sensor.

NHTSA ID

11508752

Incident

Feb 18, 2023

The contact owns a 2018 Mercedes-Benz Sprinter 3500. The contact stated that while driving at low speeds, there was an abnormal sulfur odor coming from the engine. There was no warning light illuminated. As the odor persisted, the contact’s eyes started burning and the contact also started having a headache. The contact inspected the vehicle and discovered that acid had leaked from the battery due to internal pressure inside the battery. The contact then called that dealer where he was instructed to take the vehicle in to be serviced under the vehicle warranty. The contact was able to drive the vehicle to the dealer and the mechanic confirmed the cause of the failure but informed him that his vehicle was out of warranty, despite previously being informed that the vehicle was covered under warranty. The manufacturer was notified of the failure but offered no assistance. The vehicle was not repaired. The failure mileage was approximately 7,400.

NHTSA ID

11466047

Incident

Apr 25, 2022

Mileage

7,400 mi

The contact owns a 2018 Mercedes-Benz Sprinter 3500. The contact stated that while operating the vehicle, the ABS, check engine, and cruise control warning lights illuminated. The cause of the failure was not yet determined. The contact indicated that the vehicle was recently serviced under NHTSA Campaign Number: 21V042000 (Electronic Stability Control) however, the failure occurred. The local dealer and manufacturer were notified of the failure. The approximate failure mileage was 18,000.

NHTSA ID

11440922

Incident

Nov 16, 2021

Mileage

18,000 mi

This vehicle was sold to us new with the manufacturer's window sticker stating it was equipped with a Tire Pressure Monitoring System (TPMS) as a Standard Accessory - Safety/Cargo Protection. The provided owner's manual describes the TPMS system and the low tire pressure warning lamp indicator on the dash. It was not until our first flat tire after 2.5 years and 24000 miles, that we learned our vehicle does NOT have TPMS OR a low tire pressure warning lamp. Another motorist flagged us down as it was the inside dually tire that deflated and delaminated. Luckily we learned of the deflated inner tire before the outer tire also had issues because of the extra load placed on it. We have since learned that vehicles with a GVWR over 10,000 pounds and dual-wheel rear axles are not required to have TPMS. The owner's manual does not state this and does not exclude our model as having this safety equipment. As far as we know, this exclusion is not standard public knowledge. Many heavy duty trucks with dual wheels do have such a system, so why should we question our window sticker? Our issue and safety concern is that we were lead to believe our van did have a TPMS by both our window sticker and our owners manual. Many of these vehicles are being converted to RVs (like ours but has seat belts for 6 passengers) and may be being driven unsafely due to this miscommunication. Owners/drivers of van conversions and RVs need to be fully aware of the lack of this safety feature. The dealership we bought the van from has been unhelpful and has said they have forwarded our complaint to Mercedes USA but we have yet to hear anything from them.

NHTSA ID

11440080

Incident

Oct 6, 2021

The contact owns a 2018 Mercedes-Benz Sprinter 3500. The contact received a recall notification for NHTSA Campaign Numbers: 20V663000 (Steering) and 21V042000 (Electronic Stability Control) however, the dealer informed the contact that the part for the recall repair was not yet available. The contact contacted Mercedes-Benz of Westminster (10391 Westminster Blvd, Westminster, CO 80020) confirmed the first dealer’s information. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was notified of the issue. The contact had not experienced a failure. Parts distribution disconnect.

NHTSA ID

11434749

Incident

Sep 28, 2021

On or about April 27, 2021 the driver's side rear taillight assembly randomly fell off between Phoenix and Tucson, Arizona on Interstate 10. The assembly is large, containing the taillight, brake light, turn signal light and back-up light. It could have (and may have) hit another vehicle or at least caused it/them to engage in a dangerous turning maneuver to avoid hitting the large assembly while on the freeway. In addition, the RV was then rendered unsafe and in violation of the laws of virtually every state, as well as federal regulations, due to lacking the required lighting assembly. This has also happened to another RV unit from the same manufacturer (Regency). The driver's side taillight assembly fell off this RV during windy conditions on Interstate 40 while traveling through Arkansas on April 2, 2021. There are photos of the missing assembly for both RV's. My RV was inspected by a collision repair facility in California and their determination was two fold: 1) the RV body was molded in way that would not permit the taillight assembly to properly fit in the cavity. The tolerance was off by up to 1/4 of an inch. 2) the taillight is a stock mercedes sprinter taillight assembly which has three hard point connections (top middle, and bottom. However, the body of the RV only has two points to connect the taillight assembly (top and bottom) thereby leaving the middle area open to intrusion by wind and other elements. As a result it was very difficult to find a facility to repair/replace the assembly ( they "did not want to touch it"). It has now been replaced by a collision facility which used a silicone sealant and HD velcro in the HOPE that the assembly will not fall off again in predictable weather conditions. There was no warning or other indication that the taillight assembly was going to fall off. Finally, Regency claims to manufacture just 200 to 250 of these units annually. This incident therefore involves 1% of their annual production.

NHTSA ID

11420930

Incident

Apr 28, 2021

WHEN TURNING A CORNER,ENGINE RACED TO 45 MPH WITHOUT MY FOOT ON THE THROTTLE.ALMOST LOST CONTROL.HAD TO PUT VEHICLE,MEREDES SPRINTER 3500,INTO NEUTRAL TO STOP IT.HAD PREVIOUSLY HAD THE DEALER REPAIR SPEED SENSORS THREE OTHER TIMES.WARNING LIGHTS COME ON AND I LOOSE CRUISE CONTROL.DANGEROUS CONDITION.MB SHOULD RE ENGINEER THE PART AND INSTALL IN AFFECTED VEHICLES.DEALER CONTINUES TO INSTALL DEFECTIVE PARTS.

NHTSA ID

11390039

Incident

Jan 20, 2021

Mileage

19,800 mi

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.

OM642 DPF Filter Cracked or Broken Complaint Vehicle will not start or exhibits noisy exhaust. Check Engine Lamp (CEL) is on. Multiple control unit communication and system faults may be present, including but not limited to: 134800, 134900, 11B300, 11EC00, 15E100, 155700, 162500. Additional events codes may include: 134300, 102200, 163400, 16CE00. In many cases, multiple unrelated faults are stored due to electrical disruption from wiring damage rather than indivi-dual component failure. Cause The DPF filter is cracked, broken, or leaking, allowing hot exhaust gas to escape from the exhaust system. Depending on the location of the break or leak, hot exhaust gas may be directed toward the main wiring harness and/ or the SCR (Selective Catalytic Reduction) dosing valve assembly. This heat exposure can result in: • Internal melting of wiring insulation within the harness • Short to ground conditions and loss of communication between control units • Damage to the dosing valve and/or heated AdBlue line Damage to the wiring harness may not be visible externally, as the outer tape can remain intact while the internal wires are melted and fused together. Remedy Inspect the DPF assembly for cracks, separation, or leakage. Do not proceed with further diagnosis or component replacement until the exhaust leak source has been identified and confirmed. If any damage is found, replace the DPF filter assembly. Based on the location of the failure, inspect all components in the path of the exhaust leak, including the dosing valve assembly and main wiring harness. The wiring harness must be opened in any area exposed to the exhaust leak to visually inspect the individual wires. External inspection alone is not sufficient to determine harness condition. Repair or replace any damaged wiring in accordance with approved repair procedures. Replace any dosing system components that show signs of heat damage. Failure to identify and repair all heat-affected components will result in repeat faults or no-start conditions.

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

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.

Clunking noise on load change or gear engagement Complaint Clunking noise can be heard on some load changes or when changing from N->R or N->D Cause Movement of transfer case splines Remedy Apply bearing retainer (green) Loctite to both output shaft splines of the transfer case. Loctite 648, 609 and 603 are acceptable for this repair. Note: Do not apply Loctite to input shaft (connection with transmission) splines of the transfer case else possible damage could occur.