Summary
The Mercedes-Benz Sprinter 3500 has 49 recalls spanning the 2003–2023 model years, with the most serious being Takata-type airbag inflator ruptures across 2010–2017 models where both the driver and passenger frontal airbag inflators can explode and send metal fragments into the cabin, raising the risk of serious injury or death.
The airbag inflator issue touches the widest range of model years in this recall history. Driver-side inflators on 2010–2014 models and 2015–2017 models are affected, and passenger-side inflators on 2010–2013 models and 2014–2017 models carry the same fragmentation risk. Separately, 2018–2019 models may have had airbag systems that were never activated after assembly, leaving occupants entirely unprotected in a crash. On 2013–2016 models, missing reinforcement hardware around the airbag control unit can prevent side and curtain airbags from deploying properly.
On the structural and safety equipment side, 2019–2023 models may have a partition wall with missing bolts that allows it to break free in a crash. The 2021 model year has two separate issues: seat belt retractors that can release a child seat early during a crash, and front brake hoses that can contact the fender liner, wear through, and leak fluid, extending stopping distances. For 2019–2020 models, rear brake calipers on vehicles with electric parking brakes can leak fluid into the brake system, allowing air in and reducing braking effectiveness, and fuel line clamps can loosen and create a fire risk. The 2020 model year has an additional concern with front door hinge screws that may not have been tightened, which can change how the door fits in a crash.
The 2019 model year carries a cluster of electrical and lighting issues: the instrument cluster can display a completely blank screen at startup, removing all speed and warning information; LED headlamp sensors may be uncalibrated, causing unpredictable beam angles; high-beam assist software can prevent the driver from switching off the high beams; taillights can go dark or dim when the lighting switch is turned quickly; and rear fog lamps may fail to illuminate at all. The 2017 model year has a Crosswind Assist function that can fail to apply corrective braking in strong gusts. Going back to 2015–2020, hydraulic power steering return hoses can detach, causing a sudden loss of steering assist and fluid on the road.
The 2015 and 2016 model years saw multiple fuel system and driveshaft issues. The 2015 models were built without a driveshaft catch strap, and without a protective plate and foam ring on the fuel tank, either of which can allow impact damage to ignite a fuel leak. The 2016 models had a similar missing driveshaft catch strap issue, plus a center support bearing bracket that can detach and damage the fuel system in a crash. Oil leaking from the chain tensioner gasket onto hot engine surfaces affects 2014–2015 diesels. The 2015–2016 model years also have a paint layering defect that can cause windows to separate from the body in a crash, and super-high-roof versions may be missing required crash pads that protect an unbelted front passenger.
On 2012–2018 camper and recreational vehicle upfits, the electronic stability control unit can disable itself, reducing driving stability. The
