Mercedes-Benz Sprinter 3500 Recalls

The Mercedes-Benz Sprinter 3500 has 95 recalls spanning the 2003–2024 model years, with the most serious recent issue affecting 2023 models where the main wiring harness can chafe against the drive shaft, short circuit, and simultaneously cut drive power, power steering, and brake system control while also raising the risk of fire.

The 2023 and 2024 model years carry several additional serious 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. A separate 2023 recall covers a front suspension strut bolt that can work loose and cause loss of steering. Another 2023 issue involves a 12-volt ground connection that can overheat and cut drive power. On 2024 models, parking brake cable bracket welds can fail and allow the vehicle to roll away, and longitudinal frame members may lack proper reinforcement, reducing crash protection.

The 2019–2022 era has the densest concentration of recalls. On 2019–2020 vehicles, rear brake calipers with electric parking brakes can leak fluid into the brake housing, letting air into the hydraulic system and extending pedal travel. A separate 2019–2020 issue involves fuel line clamps that can loosen and leak fuel. The 2019 model year alone has steering spindle bearing screws that can detach and make the vehicle difficult to steer, a fender liner that can chafe through a brake hose and reduce braking, an exhaust turbocharger flange that can leak hot gases into the engine compartment, and EGR pipe screws that can loosen and do the same. On 2018–2019 vehicles, the hood catch screw can be under-tightened and allow the hood to fly open at speed. The airbag system on 2018–2019 models may not have been activated after production, leaving occupants without any airbag protection in a crash. The 2019–2020 park lock software can allow the vehicle to roll after the gear selector is placed in Park. On 2019–2022 vehicles with a manual parking brake and 7-speed automatic, the parking pawl guide bushing can fatigue and also cause rollaway. The 2021 model year has a wiring harness that can chafe against the transmission carrier and short circuit, a torsion bar assembled incorrectly that can fail and cause loss of stability, and a fender liner that can contact and damage the front brake hose. On 2021–2023 vehicles, windows and interior lashing rails may be insufficiently bonded and can detach in a crash. The 2019–2023 partition wall may be missing bolts and can break free in a crash, and 2019–2021 models may have missing frame reinforcement fasteners that reduce structural stability and can allow third-row seat mountings to fail.

Going back to the 2015–2018 era, the 2015 model year has an engine oil leak from the chain tensioner gasket area that can drip onto hot surfaces and ignite, and a missing fuel tank protective plate that leaves the tank vulnerable to impact damage and fire. Both 2015 and 2016 models were built without a driveshaft catch strap, allowing a loose driveshaft to strike and puncture the fuel tank. On 2016 models, the driveshaft center support bearing bracket can detach in a crash and damage the fuel system. The 2015–2