Mercedes-Benz Sprinter 2500 Recalls

The Mercedes-Benz Sprinter 2500 has 99 recalls spanning the 2010–2025 model years, with the most serious recent issue being a 2023 main wiring harness that can chafe against the drive shaft, causing a short circuit that can start a fire and simultaneously knock out drive power, power steering, and brake system control.

The 2023 and 2024 model years carry several structural and safety system concerns. On 2023–2024 vehicles, rear axle U-bolts can lose strength and allow the rear axle to shift out of position, causing loss of vehicle control. The 2023 model year also has a front suspension strut bolt that can work loose and cause loss of steering, and a ground connection that can overheat and cut drive power. On 2024 models, frame members may lack proper reinforcement, reducing crash protection, and parking brake cable bracket welds can fail and allow the vehicle to roll away. The 2025 model year has a front radar sensor circuit board that can fail, disabling automatic emergency braking and other driver assistance features.

The 2021–2023 generation has a cluster of fire and electrical risks. A 2021 cable duct that drops out of place can let the starter-generator wiring chafe against the transmission carrier and short-circuit, raising fire risk. Separately on 2021 models, a generator wiring harness incorrectly connected to the electric power steering can cause an electrical surge with the same result. A front brake hose on 2021 vehicles can be damaged by contact with the fender liner, leading to fluid loss and longer stopping distances. On 2021–2023 vehicles, windows and interior lashing rails may be insufficiently bonded due to a paint formula issue, allowing them to detach in a crash. The 2021–2022 model years have a fuel pump that can shut down without warning, cutting drive power. On 2022 models with electrically adjustable swivel seats, incorrectly installed seat wiring can prevent side airbags from deploying in a crash.

The 2019–2020 generation accounts for the densest concentration of recalls. A 2019 steering spindle bearing with loose screws can make the vehicle difficult to steer. On 2019–2020 vehicles, a park lock software error can allow the vehicle to roll away from a parked position, and rear brake calipers on electric parking brake-equipped models can leak fluid into the brake housing, letting air into the hydraulic system and extending stopping distances. Fuel-related risks on 2019–2020 models include loose fuel line clamps that can leak and cause a fire, and an unlocked fuel pump bayonet fitting that can leak diesel onto the road. The 2019 model year alone has a loose exhaust flange at the turbocharger outlet and loose EGR pipe screws, both of which can allow hot exhaust gases to escape into the engine compartment and start a fire. A 2018–2019 hood catch with an improperly tightened screw can allow the hood to fly open while driving. On 2018–2019 vehicles, rear side windows may be single-pane rather than laminated glass, reducing ejection protection in a side impact or rollover, and airbag systems on some 2018–2019 vehicles were never activated after assembly. The 2019–2022 instrument cluster can go completely blank at startup, hiding speed, fuel level, and warning lights. Hydraulic power steering return hoses on 2015–2020 models can detach and cause