Over recent times, a growing number of Mercedes Benz Sprinter owners have voiced concerns echoing similar issues, particularly regarding maintenance expenses that frequently exceed expectations for commercial vehicles. These recurring problems have led some to consider collective action, highlighting a potential area of dissatisfaction amongst Sprinter owners.
While the prospect of legal recourse remains uncertain without specific legal expertise, the shared experiences point to a significant issue: numerous Sprinter owners are facing substantial and repeated costs attempting to resolve persistent problems. These “fixes” often prove temporary, leading to a cycle of repairs that become more expensive and frustrating than anticipated.
It’s understood that senior management at Mercedes Benz in the US were alerted to these issues several years ago. However, a resolution that effectively addresses these widespread problems has yet to materialise, leaving owners to bear the brunt of these ongoing expenses.
This article serves as an update to a previous report which has garnered considerable attention, nearing 1000 views. The aim is to further highlight these concerns and extend an invitation for engagement:
- Seeking Legal Counsel: We are interested in connecting with attorneys experienced in automotive manufacturing litigation who can explore the viability of a class-action lawsuit on behalf of affected Mercedes Benz Sprinter owners.
- Gathering Owner Experiences: We are actively compiling information from individuals and businesses who have incurred significant maintenance costs on post-2008 Mercedes Benz Sprinters and who might be interested in participating in potential legal action.
Ultimately, even if this discussion serves solely to inform prospective commercial van buyers about potential pitfalls associated with the Sprinter, it will have served a valuable purpose. Should it also pave the way for legal remedies and compensation for owners burdened by excessive repair costs, the impact would be even more significant.
We encourage you to share this article across relevant platforms to broaden awareness of these issues.
Original Concerns – First Published April 24, 2015
Please note: The following is based on personal experiences with Mercedes Benz Sprinter vans used in a commercial trucking context, averaging over 100,000 miles annually. The author is not an automotive expert, and the issues detailed primarily arose after the vehicles surpassed 100,000 miles. It is suggested that the problems experienced may be indicative of wider issues that could affect many Sprinter vehicles as they reach similar mileages, particularly concerning the EGR-DEF-exhaust system.
Having operated a fleet of 47 Sprinters over seven years within an expedited trucking business, meticulous maintenance and repair records have been maintained for each vehicle. These records, available to Mercedes Benz, underpin the concerns raised in this article, intended to warn potential buyers about a critical weakness inherent in these vehicles.
Prior to 2008, when stricter diesel emissions regulations were introduced, the Mercedes Benz Sprinter, then also sold as a Dodge Sprinter, was a robust and dependable workhorse. These pre-2008 models delivered impressive longevity, often exceeding 500,000 miles, and while maintenance was slightly more expensive than comparable American vans, their reliability and extended service life justified the cost.
Image: Example of a pre-2008 Mercedes Benz Sprinter van, known for its robust build and reliability before stricter emissions regulations.
However, post-2008, Mercedes Benz implemented a complex exhaust system to meet new emissions standards. This system includes an EGR valve upstream of the exhaust, and the exhaust system itself comprises a CDI (control unit) managing sensors and valves, a DEF pump, DEF tank, DEF temperature and level sensors, and an SCR control unit with associated components. These elements are primarily located within the engine compartment. The exhaust system itself is made up of the OXI-Cat and DPF section, and two SCR catalytic converter sections. The OXI-Cat section includes an oxygen sensor, exhaust temperature sensor, and backpressure sensor. A NOx sensor and dosing valve are situated between the OXI-Cat and the first SCR catalytic converter, with a further temperature sensor in the first SCR section and a final NOx sensor in the last SCR section. Finally, exhaust gases pass through a particulate filter.
Image: A simplified diagram illustrating the complex components of a post-2008 Mercedes Benz Sprinter exhaust system, highlighting potential points of failure.
Failure of any of these components can result in significant repair bills. A NOx sensor replacement can be around $600 (and there are two), while an EGR valve could cost between $800 and $1000. SCR catalytic converters (of which there are also two) and the particulate filter can each cost thousands to replace.
Adding to the financial burden is the variability in dealership pricing for parts and labour. Mercedes Benz dealerships, which service Sprinters, exhibit considerable price differences across the country. A simple oil change can range from $170 to $400, and exhaust system repairs show similar price fluctuations.
Further complicating matters is the inconsistent quality of repairs performed by dealerships. Numerous instances have occurred where repairs costing $2000 have failed to resolve the issue, with the engine warning light reappearing within a short distance. Subsequent visits to different dealerships often lead to diagnoses of new sensor or valve failures, incurring further charges of up to $2000. The diagnostic accuracy of Mercedes Benz dealerships regarding check engine lights appears unreliable, frequently resulting in charges for repairs that do not fix the underlying problem.
In cases of complete system blockage requiring full replacement, costs can reach approximately $6000.
The “fatal flaw” of the Mercedes Benz Sprinter, therefore, lies within the complexity and fragility of its exhaust system components. The average maintenance and repair cost has been a staggering $0.10 per mile. This is in stark contrast to American-made competitors like the Dodge Ram ProMaster and Ford Transit, where comparable costs are less than $0.02 per mile.
Image: A comparative chart illustrating the significantly higher maintenance costs per mile for Mercedes Benz Sprinters compared to Ford Transit and Ram ProMaster vans.
Another contributing factor to the high cost of Sprinter ownership is the Mercedes Benz dealerships’ approach to servicing commercial vehicles, treating them akin to luxury passenger cars in terms of pricing. For Mercedes Benz to effectively compete in the commercial vehicle market against Ford and Dodge, they need to develop a significantly more affordable exhaust system or consider replacing the diesel engine with a more cost-effective and less complex 6-cylinder petrol engine.
For businesses intending to use Sprinters as true commercial vehicles and expecting to cover over 50,000 miles annually, the Ford Transit or Ram ProMaster present compelling alternatives. Consider the routine oil change costs: $30-$40 for Ford or Ram versus $170-$400 for a Mercedes Sprinter. Over 100,000 miles, this translates to $300-$400 versus $1700-$4000 respectively. Similar cost discrepancies are observed across other routine maintenance items.
Combining inflated routine maintenance costs with exorbitant exhaust system repair bills, the overall cost of ownership for Mercedes Benz Sprinters can severely impact a business’s profitability. For a fleet of 28 Sprinter vans (2012 & 2013 models), annual maintenance and repair expenses reached a staggering $270,000 in 2014 – nearly $10,000 per van per year. Such expenses are unsustainable for many businesses. With only a 6.4% chance of a Sprinter reaching 150,000 miles without significant and costly repairs, fleet operators are increasingly switching to ProMasters and Transits as quickly as possible.
Despite reports of strong sales figures at some dealerships, it is believed that wider awareness of this “fatal flaw” will inevitably lead to a decline in Mercedes Benz Sprinter sales in the commercial market.
Mercedes Benz needs to address these issues urgently to remain competitive in the US commercial truck market: reduce parts and service costs, and reconsider the complex diesel exhaust system – the critical weakness of the Mercedes Benz Sprinter.
