What 79 owners told NHTSA about the 2020 Mercedes-benz Sprinter 2500 Cargo Van

repeated EGR clogging and malfunction: bucking or stumbling behavior, inability to accelerate properly, disabled shifting affecting ability to slow or stop without excessive use of brakes, Limp Home Mode suddenly without warning including inability to maintain a safe speed on highway and speed minimums that the vehicle cannot keep up (20 mph max while climbing moderately), unable to downshift when going downhill - relying solely on braking to keep speed below safe limit or speed limits. EGR failed again after cleaning, in as little as 3 months. No repair seems possible, only repeated cleanings. Since this happened so much, we have been in several unsafe situations due to the sudden and unheralded degradation of performance and safe use of the vehicle. Once repaired, the condition can come back immediately due to the computer still guessing that it is still in failure (limp home mode returned suddenly without warning as we merged onto an interstate with no exit for 7 miles uphill… and only made 20mph). Check Engine light could come on, and did, but never during the actual degradation of performance - and went often after a few run cycles. Mercedes dealers have confirmed and performed all services on the EGR and related issues (malfunction once caused the aircleaner element to be sucked in and that caused a MAF to be destroyed by contaminants): 1) first signs of issue before 43,000 miles (when check engine light and/or LHM happened -repaired 18sep2023, 51,871 miles, MB service code: LI14.20-N-073867); 2) 26 DEC 2023 - EGR failure diagnosed and replaced by MB dealer. Cleaning had not fixed the issue or failure was final as found by driving by technician and not by codes! 3) 09/jul/2024 - MAF replaced, EGR codes noted - but functioning, fix by MB/Canada 4) 07/24/2024 - 70,547 miles - EGR Clean by MB Missoula MT - failed upon highway same day 5) 07/25/2025 - 70,600 miles - MB Missoula MT cleared computer 6) 88,340 MB cleaned EGR - runs ok again

NHTSA ODI 11674336

There is a problem with the engine control parameters which occurs at higher altitudes. The vehicle will not produce adequate power. This is not simply normal power loss related to density altitude. This is a malfuntion where the vehicle does not respond to the throttle, and produces only about 2psi of turbo boost even upon extended application of full throttle. This problem occurs only on sprinter 4x4 models with the OM642 diesel motor. I experienced this problem for the first time yesterday when pulling onto a 2 lane highway at 7,000 feet in the sierra nevada. The vehicle began to move but as I turned uphill to cross the highway it produced no power and I was stuck straddling the center line on a blind curve. Extremely dangerous. Had to turn the vehicle off and restart it and it behaved normally until later in the day, on a steep remote 4x4 road. Unable to climb a small hill due to lack of power. Could not be resolved through any combination of turning off, waiting, warm-up periods, activating/de-activating traction control etc. Had to use winch to climb mild grade. This issue is well known to the Sprinter community and has been repeatedly reported to Mercedes Benz USA with no response or resolution. There are no warnings, messages, store error codes etc associated with this issue. Many descriptions of this behaviour can be found online: https://sprinter-source.com/forums/index.php?threads/106595/ https://windinmyface.com/Sprinter-Issues_Breakdowns-WillNotMove_RPMsDropEngineLugs.html https://sprinter-source.com/forums/index.php?threads/103019/#post-1130969 https://sprinter-source.com/forums/index.php?threads/94746/ There are many more. This is a known issue, relating to engine control software, that is very dangerous and the manufacturer has taken no steps to remedy. It is beyond time for regulatory intervention. Thank you.

NHTSA ODI 11470956

I purchased my van Feb 5, 2021 with 8 miles on it. By April, it was hesitating intermittently at low speeds. It got progressively worse. MB of Athens could not diagnose it in 2 visits in May and June of 2021. By August, the Sprinter service manager at RBM of Atlanta, Charles told me on the phone that he was sure it was the EGR valve and none were available. ETA of a valve was Nov, 2021. The date then moved to Jan, 2022. It is April and there are no EGR valves in the world to be put on my van. The hesitation has progressed to higher speeds. I am going to be killed in this van, my only work van, as I never know when the hesitation will occur. It is dangerous. Mercedes knows they have a problem. I have 2 MB Customer Care complaint files and no results. This problem is a result of their faulty emissions system. I know they are fully aware and do not want to admit their issue and take liability. I bought this van on the MB reputation for quality and service as my job depends on it. I am scared to drive it, but must make a living. I need help. The public should be made aware. I know I am one on many, many with this issue and no resolve. They continue to manufacture new vans in Charleston, SC daily with EGR valves. This is wrong. Please respond. Thank you!

NHTSA ODI 11460110