2009 Smart Fortwo

On April 30, 2018, Mercedes-Benz USA, LLC, (Mercedes-Benz) submitted a Defect Information Report (DIR) to NHTSA regarding a defect that could result in a vehicle fire starting from the engine compartment in 42,781 model year (MY) 2008 and 2009 Smart Fortwo cabrio and coupe vehicles (451 platform).According to Mercedes-Benz?s DIR, ?the rear insulation mat within the engine compartment might deform, deteriorate, loosen and over time, subsequently be able to contact hot components of the exhaust system.This could lead to an ignition of the insulation mat and possible fire in the engine compartment.?The US-specification exhaust system has an external catalytic converter packaged close to the insulation mat, where temperatures in the vicinity of the insulation mat reach high values.Over time, these temperatures can lead to a change in the insulation mat's material characteristics and ultimately allow the material to deform. Depending on the magnitude and the specific location of the deformation, the insulation mat could contact hot components of the exhaust system and ignite.Mercedes-Benz will replace the rear insulation mat on the affected vehicles with the improved mat first implemented in the United States in MY 2010 vehicles.ODI?s analysis of fire incident field data reported to NHTSA and Mercedes-Benz show an increasing trend of non-crash fires in the subject vehicles that begins after 4 years of service and accelerates after 7 years of service.The analysis shows that this trend is driven by fires occurring in the engine compartment.Forensic investigations of fires occurring in the past year identified the insulation mat as a likely or possible cause of most of the fires originating in the engine compartment.This investigation is closed based on Mercedes-Benz insulation mat recall.For more information about field data trends and fire investigations, see the closing resume in the document file for this investigation.

On December 16, 2016, the Office of Defects Investigation (ODI) opened Preliminary Evaluation PE16-016 to investigate eight complaints alleging incidents of engine compartment fire while driving or shortly after engine shutdown in model year (MY) 2008 through 2009 Smart Fortwo vehicles.The complaints appeared to indicate an increasing trend, with all eight fires occurring since January 2015.As part of PE16-016, ODI analyzed information related to incidents reported to the Office by consumers, analyzed field data and technical information submitted by Mercedes-Benz USA (Mercedes) in response to the PE16-016 information request letter, and analyzed non-crash vehicle fire claim data provided by the Highway Loss Data Institute (HLDI).To date, ODI's analysis of incidents reported by consumers and provided by Mercedes has identified 27 incidents of open flame fires originating in the engine compartments of the subject vehicles, 14 of which were reported to ODI by Vehicle Owner Questionnaires (VOQs) and 18 involving complaints or field reports to Mercedes (5 of the incidents were reported to both ODI and Mercedes).One incident reported to Mercedes includes an allegation of an injury from smoke inhalation.Nineteen (19) of the incidents occurred since January 2015.Mercedes has only investigated 2 of the 27 fire incidents, and the company was unable to identify a vehicle-based cause for either incident.To further assess incident rates and trends, ODI requested fire claim data for the subject vehicles and eight peer vehicles from the Highway Loss Data Institute (HLDI).HLDI collects insurance claim data from companies representing over 80 percent of the market for private passenger vehicle insurance in the United States.ODI?s analysis of the HLDI data, which covered the period from 2010 through late-2016, found that the MY 2008 Fortwo vehicles had a significantly higher claim frequency than its peers and, similar to ODI?s complaint trend, experienced a sharp increase in claims in 2015.This investigation has been upgraded to an Engineering Analysis (EA17-003) to continue to investigate the high frequency and increasing trend of non-crash engine compartment fire incidents in the subject vehicles.The VOQs associated with the opening of this investigation were:10676359, 10780222, 10790017, 10820891, 10872656, 10944676, 10916505, 10924311, 10924637, 10939504, 10945296, 10993895, 11011100, 11011565.

The contact owns a 2009 Smart Fortwo. The contact stated that while driving at various speeds, the vehicle suddenly lost motive power. The vehicle was turned off, the contact waited, and then restarted the vehicle, and the vehicle operated as needed. The failure had occurred several times while driving. The contact stated that while depressing the brake pedal, the vehicle failed to brake immediately and drifted to the left. The brake pedal was depressed to the floorboard for the vehicle to come to a stop. The ABS warning light was illuminated. The vehicle was taken to the dealer, who diagnosed that the ABS was faulty and retrieved Diagnostic Trouble Codes: 1314 and C1443. The contact stated that the front brake pads were replaced by the dealer, and the rear brake pads were replaced by a certified mechanic. The vehicle was not repaired for the failure to accelerate, and the failure persisted. The vehicle was purchased on July 17, 2025, and the seller kept the repair issues with the vehicle from the contact and failed to provide information on the previous repairs. The contact stated that the failure recurred after retrieving the vehicle. The manufacturer was not informed of the failure. The failure mileage was 74,254.

NHTSA ID

11682335

Incident

Jul 31, 2025

Mileage

74,254 mi

The contact owns a 2009 Mercedes-Benz Smart ForTwo. The contact received notification of NHTSA Campaign Number: 18V273000 (Engine and Engine Cooling); however, the part to do the repair was unavailable. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The manufacturer scheduled an appointment at the dealer; however, the dealer contacted the contact and decline to honor the recall repair appointment. The contact contacted two dealers and was informed that they do not perform repair on Mercedes-Benz Smart Cars. The contact had not experienced a failure. Parts distribution disconnect.

NHTSA ID

11612872

Incident

Sep 5, 2024

The contact owns a 2009 Mercedes-Benz Smart Fortwo. The contact received notification of NHTSA Campaign Number: 18V273000 (Engine and Engine Cooling); however, the part to do the recall repair was not yet available. The local dealer and several unknown dealers were contacted and informed the contact that they did not service Smart vehicles. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The contact had not experienced a failure. Parts distribution disconnect.

NHTSA ID

11611680

Incident

Aug 29, 2024

When starting the car, the transmission will not respond to the shifter being put into any gear. A computer diagnostic says it is a communications issue. Mercedes, who sold the car to me new, refuses to do any repair work as they have discontinued Smart sales in the US. If the communications for the transmission fails during operation, this will be very dangerous. There are numerous reports on the internet of similar issues and owners trying to repair this themselves. Mercedes needs to be forced to repair what they have sold and represented. If this is a software update issue, who has the software to fix this issue? It is outrageous that NHTSA has not enforced these issues with Mercedes Benz of America.

NHTSA ID

11606245

Incident

Jul 1, 2024

The contact owns a 2009 Smart ForTwo. The contact stated that on multiple occasions when the vehicle was parked and the gear shifter was shifted, the transmission would only shift into neutral. Additionally, the contact stated that the vehicle failed to respond when the accelerator pedal was depressed. Additionally, the tire pressure warning light was illuminated. The vehicle was towed to an independent mechanic but was not diagnosed or repaired. The contact also received notification of NHTSA Campaign Number: 18V273000 (Engine and Engine Cooling) however, parts to do the recall repair was unavailable. The manufacturer was not notified of the failure. The failure mileage was approximately 37,000. Parts distribution disconnect.

NHTSA ID

11520076

Incident

May 2, 2023

Mileage

37,000 mi

2008 Smart Fortwo has a recall open for reprograming the transmission computer because of rough shifting and bucking while shifting and lugging the engine to much before down shifting. Mine is a 2008 but the VIN was not included in the recall and I am having the same problems with mine. Can mine be added to the recall?

NHTSA ID

11490643

Incident

Oct 24, 2022

The contact owns a 2009 Smart ForTwo. The contact stated that while starting the vehicle, the air bag warning light was illuminated and would not turn off. The contact took the vehicle to an independent mechanic where it was diagnosed with needing the driver’s side air bag replaced. The vehicle was not repaired but was pending repairs. The independent mechanic had to order the parts for the repair. The dealer was contacted however, the dealer was unable to confirm when the part would be available. The manufacturer had not been informed of the failure. The failure mileage was approximately 127,000.

NHTSA ID

11450806

Incident

Nov 8, 2021

Mileage

127,000 mi

Fuel pump connectors cracked leaking fuel.

NHTSA ID

11441187

Incident

Nov 13, 2021

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 There are several types of complaint about noises or poor windshield wiper wiping performance: A: Wiper blades squeaking, chattering, shuddering B: The windshield is not wiped completely (streaking) C: During the downward movement water is pulled back onto the windshield from the A-pillar (Figure 1) D: After windshield cleaning, water keeps spraying onto the windshield for several wipe cycles (Figure 2) A1: The windshield and wiper blades are contaminated with residues from car washing facilities, identifiable by the water beading. The resulting differences in the friction values between the wiper blades and the windshield can excite the wiper blades to vibrate. Note: It is mostly wax residue from the washer system, but also water-repellent nano-particle coating for paint and/or silicone-based washer fluid, that could cause this problem. A partially dry windshield also has different friction values, which can likewise result in squeaking of the wiper blades A2: The wiper blades are worn by mechanical damage (wiper lip damaged by ice or insect debris, or deformed by long periods of disuse). A3: Incorrect angle of incidence of the wiper arms to the windshield. Because of this, the rubber lip of the wiper blade may not flip over at the reversal point. Cause B: B1: Wax/ dirt residues on the windshield B2: Wiper blades deformed or worn B3: Downforce of wiper arm not OK (Figure 3) Cause C: Water is pulled back onto the windshield by the differential pressure created as the wiper arm moves downwards. Cause D: Washer water collects in the fastening of the wiper blade and is blown onto the windshield by the airstream over several wipe cycles. Note and supporting information: Wiper blades are wear parts which, even when "not used" for long periods (kept in park position), may become permanently deformed and damaged. Further stresses on the rubber wiper blade arise due to various environmental influences which progressively change the effectiveness of the rubber wiper blade and accelerate the aging process. Due to the natural aging process and wear, the wiper blades should be replaced twice a year, preferably in Spring and Fall (see operator's manual). Remedy Remedy A: A1: Cleaning entire windshield with A 000 986 40 71. A2: Checking water's flow behavior after windshield has been cleaned (see Video 1). If, after cleaning, there are still areas with water beading, then the cleaning process must be carried out again until a rejection reaction is no longer present. • Note: On the vehicle in the video (Video 1), water still beads on the bottom left of the windshield. The windshield is still not properly clean, even though it appears to be clean. The windshield is only properly clean when there are no more areas on the windshield where water beads. A3: Replace wiper blades with genuine wiper blades. Important: Only exchange wiper blades if windshield no longer has water-repellent areas Note: Replacement of wiper blades is not covered under warranty and can be replaced at the expense of the customer. Remedy B: B1: Clean windshield with intensive cleaner A 000 986 40 71. Important: Do not clean the wiper blades otherwise the graphite coating will be damaged. B2: Replace wiper blades with genuine wiper blades • Note: Replacement of wiper blades is not covered under warranty and can be replaced at the expense of the customer. B3: Check the wiper arm for excessive resistance in the bearing. Restore mobility or replace wiper arm if necessary. Remedy C: Problem inherent in design for which there is no technical remedy. Exception: X204 up to 02/2014. In these vehicles, it is possible to install the design configuration of vehicles as of 02/2014. This includes wiper arms (styled arms) with improved behavior in this respect. It is also necessary to replace the wiper blades because the styled arms feature a Top Lock connection (previously Side Lock).

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 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

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. Remedy NOTE: If a pressure compensation diaphragm is fitted in the housing cover, then the lamp unit is a "closed system". Headlamp: Remedy 1 Clearing fogged/condensed LED headlamps and LED rear lamps: 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 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). 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 the formation of condensation, check the headlamp for damage. (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 damaged 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 in accordance with LI82.10-P-078896 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.

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. 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.