2024 Mercedes-Benz Sprinter 3500

The contact owns a 2024 Mercedes-Benz Sprinter 3500 equipped with Kumho Tires, Tire Line: Crugen Premium, Tire Size: 215/85/R16, DOT Number: 1H23PLDV9. The contact stated that while driving 65 MPH with his wife and dog inside the vehicle, the contact heard an abnormally loud sound coming from the front passenger’s side wheel. The contact slowed down and parked the RV at a local gas station. A dealer was not contacted. The vehicle was not taken to the dealer or an independent mechanic to be diagnosed. The tire was replaced. The manufacturer was notified of the failure and was examining it. The failure mileage was approximately 5,000.

NHTSA ID

11728494

Incident

Mar 27, 2026

Mileage

5,000 mi

We purchased a new 2025 Jayco Melbourne and afterwards discovered the MBZ 3500 Chassis was a 2024.(6/19/2024) A 2025 MBZ 3500 chassis has a TPMS -factory installed system; 2024 no TPMS. I started to install an aftermarket TPMS and noted the tire valve stems were rubber. I couldn’t install the end cap sensors due to safety concerns about centrifugal force causing a failure of the rubber valve stems on the wheels. My next contact was MBZ customer service. They referred me to Walter’s Mercedes-Benz Van Center, 7979 Auto Drive, Riverside, Ca. 82504. I contacted Service Advisor Brennan Ruiz at 951-552-2145. After a couple of phone calls back and forth and me researching the parts through MBZ, I made an appointment on 6/11/2025 to have my 2025 Jayco retrofitted with the factory TPMS. The cost for me was approximately $3;000.00 including parts and labor. On 6/112025, Brennan took care of a warranty issue not related to this and was very helpful with the TPMS retrofit process. He did inform me that his tech would not be able to install the parts due to MBZ on the east coast refusing to release the computer code unless there was prior documentation or campaign bulletins for reference. The TPMS is standard on the 3500 MBZ Sprinter chassis, but MBZ will not release the code to their own dealership when I am willing to pay $3,000.00 for the entire retrofit process. It does not make sense to me since MBZ has the Motto on their web site: “How Mercedes-Benz Safety Features Prevent Accidents Before They Happen.” That’s what I am attempting to have completed! Resolution: First, I want this documented in case of tire failure/accident. Secondly, hopefully this will help me getting the Factory TPMS retrofit completed! I am not asking MBZ to pay anything other than releasing the computer code for the retrofit. This is for the safety of my family and all the other motorists that I encounter while driving on the highways in the US. Thank you for your help,

NHTSA ID

11666477

Incident

Jun 11, 2025

Tried to drive over Wolf Creek Pass in Colorado. About halfway up, the vehicle started losing power and eventually lost all power. The engine was running but even with the pedal to the floor it was totally unresponsive. This put us in a dangerous situation as I had to park on the side of the road with huge drop offs and semi trucks. I managed to turn it around to come down the pass coasting. The engine finally became responsive again at lower altitude. The yellow “check engine” icon was on when this started. Managed to come back to Pagosa Springs and shut it down several times and re started. The engine light finally went off.

NHTSA ID

11612146

Incident

Sep 2, 2024

An authorized Mercedes-Benz eSprinter dealer will update the drivetrain control unit on the affected vehicles. An authorized Mercedes-Benz Sprinter dealer will update the engine control unit on the affected vehicles.

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 The check engine light is activated, accompanied by one or more of the following fault codes related to the Boost Pressure Positioner: • P300A6D The boost pressure is too low. Charge Air Cooler. • P300974 Component 'Boost pressure positioner' has a malfunction. The boost pressure is too low. • P300DFB Component 'Boost pressure positioner' has a malfunction. • P300DE8 Boost pressure control A has a malfunction after the cold start. Cause The potential causes for these fault codes are: A. Leak or Blockage in the Intake or Charge Air System: This can prevent the proper flow of air, affecting the boost pressure. B. Insufficient Source Vacuum, Vacuum Leak, or Sticking/Weak Vacuum Component: These issues can prevent the boost pressure positioner from functioning correctly. • For Model Year 2023-Cuurent vehicles operating at approximately 4,000 ft elevation or above, reduced ambient pressure and/or high brake demand may contribute to reduced available vacuum differential and under boost com-plaints, even when no discrete vacuum component failure is identified. C. Internal Malfunction of the Boost Pressure Positioner: The component itself may be faulty. D. Internal Defect with the Variable Turbine Geometry (VTG) System inside the Turbocharger: Issues within the turbo-charger can affect boost pressure control. Remedy Engineering Review Required: For vehicles operating at approximately 4,000 ft elevation or above, a TIPS case MUST be opened before replacing any component for fault codes P300A6D, P300974, P300DFB, or P300DE8.

Complaint The customer reports an exhaust odor from the engine compartment, potentially accompanied by a check engine light and/or engine misfire. Cause The injector hold-down may fracture due to material-related factors, allowing the injector to lift from its seat and resulting in combustion gas leakage past the sealing interface. Remedy Carry out repair measures in accordance with the extent of damage determined during inspection. Replace only tho-se components identified as faulty or compromised by the failure, including the fuel injector, sealing ring, injector hold-down, hold-down bolt, high-pressure fuel line(s), and, if required, the fuel distributor (rail). All work involving fuel injector removal and installation must be carried out in accordance with WIS document AR07.16-D-1020TSM. Particular attention must be given to the proper preparation of the injector bore and sealing in-terface. All carbon deposits, combustion residue, and surface contamination must be fully removed to ensure correct injector seating and sealing integrity, thereby preventing combustion gas blow-by and repeat failure.

Complaint The customer reports that the engine cranks but does not start, or only starts after extended cranking. A check engine light may be present, and fault codes P300616 (The fuel pressure in the system is too low) and/or P300617 (The fuel pressure in the system is too low) may be stored, along with other fuel pressure-related fault codes. Cause Insufficient high-pressure fuel build-up during engine cranking. The fuel system does not achieve the required rail pressure of >120 bar, preventing engine start. This condition may be caused by internal leakage within the fuel injection system, inadequate fuel supply from the low-pressure circuit, or a malfunction of the high-pressure fuel pump. Remedy 1. Verify high-pressure fuel rail pressure during engine cranking using XENTRY actual values. • Evaluate the actual value “The starter turns and the combustion engine does not start” and monitor high-pressure fu-el rail pressure during cranking. (See attachment: XENTRY actual values – rail pressure not reaching >120 bar) • The system must achieve a minimum of >120 bar in order to enable engine start. → If the specified rail pressure is not achieved, perform the following checks: 2. Check low-pressure fuel supply • Verify fuel quality (color, clarity, separation, contamination) • Inspect fuel tank, fuel filter, and low-pressure fuel pump for debris, restriction, or damage • Measure low-pressure fuel supply before and after the fuel filter and confirm values are within specification • Perform a fuel volume test at the high-pressure pump inlet to ensure adequate delivery • Verify that the injector leak line is installed correctly, remains unmodified, and is not restricted or kinked → If low-pressure fuel supply is not within specification: Repair as necessary and recheck high-pressure fuel build-up 3. Check for internal leakage within the fuel injection system • Perform a fuel injector leak/return test using XENTRY • Evaluate injector leak-back during cranking NOTE: If the combustion engine does not start, perform the test by cranking the engine 3–4 times for approximately 15 seconds each, instead of allowing the engine to run for approximately 60 seconds → If injector leakage is present: Replace the affected injector(s) and perform injector teach-in 4. Check high-pressure fuel system • If no leakage is identified and low-pressure supply is sufficient, evaluate high-pressure fuel generation → If high-pressure fuel system does not generate sufficient pressure: Replace the high-pressure fuel pump 5. Final verification • Verify that rail pressure exceeds >120 bar during cranking • Confirm the engine starts normally without extended crank • Clear fault codes and perform final validation