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Dodge Sprinter Maintenance



  • I truly sympathise with your situation - the problem really is that these car companies are only interested in getting vehciles off their lots and into the hands of the banks and finance companies who will ensure you pay for the vehcile regardless of how badly it performs.
    Its sad to say that this is historical and will continue until WalMart starts to sell cars and trucks when you can simply take the vehcile back and get a refund.
    I have a 2007 Sprinter and have had my oil changes done every 10,000km at the Valvoline Centers. They are efficient and courteous costing about $70 when I provide the filter.
    In error I took my Sprinter to the dealership for the 32,000km service/oil change.
    They overfilled the engine which caused my oil light to flash and a warning to show that I needed to bring the vehcile back to a dealer immediately for fear of damaging the engine.
    Rather than risk taking it back, I stopped on the highway and got under the van and drained about a pint out of the sump. This solved the problem.
    The next day I received an email from the dealership advising that Chrysler would be sending me a form to complete regarding my satisfaction with the service and that IF I WAS NOT SATISFIED, I should call the dealership rather than mention the fact on the form.
    Hmm, I wonder why?
    Anway I did reply to the dealership and am currently awaiting their response.
    Bye the way, the dealership charge for that oil change was $235 - almost 3 times the changes of Valvoline !!!
  • kenbakerkenbaker Posts: 239

    Now these guys are telling people that they need a fuel filter, and sometimes an Air Filter every time you get oil changed... b... s... some are trying to demand oil changes on a short schedule (they don't know the product, but they know how to charge extra).

    My stealership didn't even use the right oil, didn't fill it up, or both. Wonder how much your dealership put in yours? Wonder how much it sucked on through the breather system before you drained the pint out?

    They tell me they want $160 for a fuel filter change!!!

    KenB :confuse:
  • I have a 2006 2500 used for commercial purposes with 23k miles. Hve been noticing a fuel smell in the drivers compartment. Anyone else had this problem or know the cause. I am tired of taking to the dealer, even though it is still in warranty. It takes them three days to determine what the problem is. So far, they have wanted to replace the main wiring harness, said the gromet came loose at the firewall. I would not let them. I was also charged $235.00 +- or oil change & fuel filter. They put too much oil in & the light came on. They drained a quart (according to the service writer) but would not give me a refund. When I talked to the svc mgr I learned that they have not been using Mobil 1, even though they had led me to believe this. I called the Fleet Sales Manager & asked what the problems are & why should I buy another truck from him. He passed me to the svc mgr.
  • kenbakerkenbaker Posts: 239
    You don't even need a fuel filter until 30K...

    But that has not kept the dealerships from coming up with a schedule that includes a fuel filter at every 10K oild change... and charging WAY too much for one.

    This time of year the diesel tends to have more kerosene, and more smell... however, you should have very little of this anyway. You could have a small fuel leak, and should check all hoses, connections, filter, etc. for oily/dirty stains and especially for fresh fuel leaking (double check around the top of the fuel filter that they changed. Other possibilities would be certainly supect as warranty work: (injector, glow plug, or fuel rail leak).

    Also, if you use the Aux. Heater this time of year (when it tends to be cold), then you need to remember that it does have bit of smell especially until it gets up to speed... In extreme cases you will see some white smoke from the drivers side wheel well. The smell from the Aux. Heater is much less if you use it every month for 10 minutes as mentioned in the owner's manual.

    A few bugs in the batter (dealers/reps) and this is one bad streak for Dodge with a vehicle that is known worldwide for quality and longevity.

    Please fill out the dealership review on this website for your location. We need the input.

  • sppspp Posts: 13
    Posts: 4
    Status: Online!
    Post #1
    I have the original front brake pads and rotors on my 06 sprinter. I have 28k on them. I had a dealer check my brakes and he told me I have about 2k left on the front pads and about 5k left on the rears. The front rotors have never been cut and the pads still have life and have not gone metal to metal, however, the dealer tells me I need new front rotors! I have never heard of this before. Is it possible to need new front rotors even if they have never been cut or the pads have never worn down to metal to metal? The dealer further states that if I choose not to replace the rotors but only the pads, that he can't guarantee that the brakes would not pulse and that they probably would not have the expected life. Am I being scammed. I hear the dealers get more training on scams then they do on vehicle maintenance!
  • hello, spp:

    my experiences with my 2005 sprinter van 2500 have been decidedly different from yours, and i imagine my experiences more closely duplicate the thousands of other satisfited sprinter owners who have kept this van in high demand around the world. it seems to me you got one of the 'lemons' in the group, as well as having to deal with support staff at your dealership who probably took on the sprinter franchise as a lark.

    my sprinter has 30000 miles; i haven't had any serious problems. the only problem i can think of right now was a dash warning light that woudln't go out and the dealer (sam lehman's in peoria il) took care of it right away. this dealership has treated me very well and i can truly sing their praises. i'm going back thu for the 30000 mile service. soon after that, it will be off warranty but i may still take it there for service. i'd also like to add that i get around 26-30 mpg on all-day interstate travel (admitedly, at 55 mph) and around 23-26 mpg on town stop-n-go travel.

    i'm sorry you've had such bad luck. and i'm hoping i won't have any bad luck in the future with this vehicle, but right now, i'm pretty happy with it.

  • Greetings all,
    158 HiTop,dual sliders 1set of passenger seats added. I recently had a problem losing power and engine would shut-off with an engine light. It would fire right back up but shut off again soon after. Went to dealer I bought from, repaired a trans leak (they say, I never saw fluid on pavement), and replaced fuel filter.When they drove it ,another engine light. Now it's a glow plug and a glow plug module. Truck has 73k, 2005 model. It's under warranty until July 2008. Is this covered? Are injectors covered? I read in another post not to use biodiesel because factory fuel filters are cellulose and will melt and clog. Anyone experience this? Is there a different brand filter (i.e. NAPA, Fram) that will not do this? Anyone remove the oil filter cover? In an odd place and difficult to remove/replace. Any ideas greatly appreciated. I try to bypass the Stealership as much as possible... Joe
  • kenbakerkenbaker Posts: 239
    Transleak, probably an "O" ring on a sensor, not a major leak, more driving under pressure, doesn't continue to leak much.

    Glow plugs/control probably on emmissions/engine warranty, but must ask dealer.
    Injectors are as far as I know...

    Fuel Filter (price to replace?) how many times have you done it?

    Biodiesel approved up to about 5 or even 10-15 percent bio source, but only if approved/tested quality, like ASTM. Cellulose not likely to melt, clog yes, but only if the previous petroleum diesel was very dirty (biodiesel cleans remarkably well, and lubricates very well too). Clogging of fuel filters in diesel operation (clean fuels assumed) is from very COLD fuel with adequate amounts of parafins (summer fuel used at winter temps) and/or emulsions (hot/cold/hot/cold condenses moisture which mixes with the oils and emulsifies (hard to filter/pump) and easy to freeze).

    Some filters for the Sprinter are available that are known as "fleece", but you will have to go searching, I don't have a source at this time.

    There are people running Sprinters on B85 and even B100 (B = bio, number =percentage of). A few are also reporting running as converted to use SVO (straight Vegetable Oil, most reclaimed, VERY HIGHLY filtered).

    Oil filter cap/holder very easy to remove on US Sprinters up to 2006 (5 cyl. Diesels), actually very unlikely to spill/drip on engine. The housing drains into the block. I use the nesting set of filter wrenches (7-in-one) and a regular 3/8" extension/ratchet... Remove after draining most of the oil, or the flow out the bottom is a torrent... wow, can shoot out over the side of the catch pan.

    In putting the cap/filter back in, be patient, use the new o-rings, only tighten to touch down... plus very little torque... this seals by o-rings in a sleeve, not by pressure on a gasket/flat surface.

    Easiest oil changes I have ever had (except for using 9.5 quarts of oil...)

    KenB :shades:
  • I have an 02 dodge sprinter. The alarm doesnt work. The light on the central locking system blinks that the passenger side doors are not closed properly. They are closed, however the sliding door is tricky to close it needs some persuasion. Any suggestions on how I can trouble shoot this my self.
  • I had the same problem on my 2006 Sprinter, the second day I owned it. There was a fuel leak at the front of the engine where the 8mm fuel supply/return hoses are clamped to the injection pump. The dealer was unable to find the leak, so I made the repair myself with the proper clamp. That was at San Jose Capital Expressway Dodge. They are really useless, and even the management doesn't want to take responsibility or keep the customer happy. They neglected to respond to my letter of complaint. The unfortunate thing about the US is that auto mechanics don't have the training or understanding of how to properly fix a car. They are trained on Detroit farm equipment, and when they come across a foreign car, they are unable to apply what they learned in training.
    This is why such wonderful vehicles such as the Sprinter and the VW vanagon have such a bad reputation. I am a former auto mechanic, and after my training I worked with a German master technician. There was so much that I didn't know, even things that now seem so basic. I had to make a paradigm shift in order to
    understand these vehicles. I had to unlearn much of my school training.

    Good luck with your repair
  • I had a problem with a misaligned sliding door on my 06.
    The dealership was unable to align the door. Their solution was to slam the door harder. If you carefully look at the mechanism and with the help of an assistant adjust the sliding door and the strikers, then at least the slider will work fine. Then you can make your diagnosis of the electrical problem knowing that it is not a door
    alignment problem causing the door switch to think the door is open.
  • kenbakerkenbaker Posts: 239
    Clean and lube all of the contacts for all of the doors that have them, especially the sliding and rear doors as they rely on the contacts for the elcetronics that "see" whether or not they door latches are actually set for lock mode.

    The central locking module (aka the central locking timer) is also a common point of failure.

  • ososlickososlick Posts: 12
    I have a Winnebago View Motorhome on a 2007 sprinter 2500 with the mercedes v-6 turbo diesel chassis. Can someone tell me where the locations of the engine oil filter and oil drain plug are on this unit.
  • yeayeayeayea Posts: 4
    ">I would like to know the reason why you are not allowed to change the direction of the tire rotation. The owner manual on page 196 say the rotation should not be reversed. Why? ">
  • windoverwindover Posts: 1
    I have a problem with my glow plug light staying on in the dash. Is there a way to check my glow plugs with an ohms meter at the plug of the contoller? If so what type of reading should I expect?

  • kenbakerkenbaker Posts: 239
    I have the I-5, but would guess that the drain plug is low on the pan on the driver's side. Many would say that the more efficient way to change oil is to suck it out of the dipstick tube and leave the drain plug alone. Easy if you have a vacuum source, a simple tool and a proper container.

    Mercedes uses a cartridge filter mounted high on the engine, usually on the driver side as well. Look for a black cap, point straight up that looks a bit like the bottom of a canister-type oil filter... use a matching filter wrench "cup"... all seals on this unit are "o"-rings and must be replaced every time you change oil (they come in the filter box). lube the o-rings and install by hand only, then gently tighten (the o-rings seal, the torque-down does not enhance the seal... so don't over-tighten).

  • jdetwilerjdetwiler Posts: 1
    Where would I find a maintinance manual for 2005 mercedes sprinter van. Please send your answer to Thank you.
  • Hi,

    I purchased a service manual for my 2006 sprinter directly from Chrysler publications.

    The only drawback I saw is that it was only available on CD, not book form.

    Maybe even check ebay

    good luck
  • I am finally going to put new brakes on my 04 Sprinter cargo van. I have the 140" wheel base with 16" tires 2500SCH. It is the first set of brakes and I have 60,000 mi. on them. Needless to say they are metal to metal. The problem I have is finding pads and rotors for this van. NAPA wants to know if I have the Bosch calipers. It turns out I do have Bosch calipers, took the front tire off to find out,hope the rear is the same. Now they want to know what size rotor I have. Apparently there are three different sizes listed in millimeters. How can I tell what size the rotor is? Are there any special concerns I should watch for when I finally get all my brake parts together? By the way I love this vehicle. Only two minor recalls that I am aware of and no major problems. They do need to learn how to paint this vehicle properly. And why after 4 yrs. can't I find a repair manual for this vehicle? By the way, I purchased my van from Fyda Freightliner in Columbus, Ohio and they have been very courteous and fair and timely with the recalls and scheduled maintenance I had them do while the vehicle was under warranty. After warranty I started doing my own scheduled maintenance. You do not have to go to Dodge or Chrysler dealer if there is a Freightliner dealer selling Sprinters near where you live.
  • Hi,

    Usually I get my parts from They now carry some maintenance parts like filters. I just checked for your brake parts to no avail.

    Some other sites to check are and the links from that website.

    Does the Freightliner dealer sell these parts? These sprinters have been around forever in other countries; maybe there is a parts source in Canada.

    Regarding the shop manual, I found a CDRom factory manual from chrysler publications, but it is not as straightforward as having a paper manual.

    Good luck

  • Does anyone know where to find the axle codes on a
    2005 Sprinter?
  • Had similar problem on 04 bought used. Dealership wanted outrageous price to replace glow plugs, module, and injectors. Did not allow work as van drove very well untill cutting out suddenly. Usually running fine after restart, other times having to wait 15 minutes to an hour to run. Don't see how glow plug problems could ever cause a stopping problem once the engine is running. Finally took to second dealership as loosing power too. They quickly found a short in the wiring harness which was probably causing the error messages. After picking up and driving home, the engine light came back on. Found out the egr valve was bad I would guess as a result of my continuing to run with the wiring problem. After replacing it myself, the van has run very well, am extremely pleased. Only other problem since has been the negative battery cable. Connections very clean, cable looked new but high resistance and warm after trying to start so you may check that as well.
  • Hi, Tim here.

    I own a 2007 cargo van extended model 3.0 diesel with 53k miles on it. I change my own oil. Oil change is every 10,000 miles with special synthetic mobil 1 esp formula for diesels usually only available at dealer.
    12 quarts.
    Oil filters can be found at Napa auto parts or dealer. Napa is $10 bucks cheaper than dealer.
    It is a canister style with an filter element. Loosen the 84mm 14 flat canister cap nut and drop in the filter element. Canister cap nut needs to be properly torqued at 25ft lbs.

    The problem with changing the oil on the 3.0 diesel is the 84mm 14 flat canister filter cap nut. You need the correct size cap nut tool that a torque wrench will fit to torque the cap nut properly.

    I custom machine a one piece 84mm oil filter wrench cap nut tool out of 100% billet aluminum just for the 3.0 mercedes diesel and sell it on ebay for $79.00 (free shipping in USA). If your interested just type in sprinter oil filter wrench under (all categories). My ebay member name is ibidfortwo. Transmission is also kind of funny. Mercedes does not have an dip stick for the automatic transmission. Yes there is a place to insert a dip stick. I think the dip stick can be bought at the dealer for about $150.00 (special order). I know. It is crazy having to buy a dip stick for $150.00 to check your own tranny fluid.

    In my opinion the Dodge Sprinter diesel is a great vehicle and I would not hesitate to buy another one.
    Hope this helps you.
  • Just bought a 2008 Gulf Stream motor home on a Sprinter chassis. It has a 3.0 Mercedes Diesel (lovely unit :blush: ). I see that it has a cartridge canister type oil filter. I would like to get a couple oil filters in preparation for upcoming 10,000 mile scheduled maintenance. Does anyone know what filter this calls for?
  • Please advise where is the tension adjustment for the fan belt so I can change
    my worn belt. Thanks
  • I own a 2007 3500 and found to be a good source for oil, filters, brakes etc. Just changed the oil and filter in the trans. Not a big deal. Used 6.5 liters of fluid. Dipstick purchased from web site. Dealer said the transmission would have to be jacked up to access. I found it was very tight but managed without moving the trans. I think next time I will move it about a 1/2" to make the job easier. I had to place the filter and gasket inside the pan get it in place and then reach inside and insert filter and position the gasket. The Fusch fluid sold in addition to the MB fluid works well. The shifting is even better than when it was new. Note- the trans filler tube is under the atifreeze overflow. You will be sent a new red lock for the top when you order a trans kit from the site above. Hopefully this will help a few people.
  • jftfijftfi Posts: 10
    Have a 2004 High top loaded and purchased new. I have always had the maintance work done at the dealer to insure warranty. I now have 78,000 miles on my truck and in the process of repairing another trans leak myself (3rd one). Power train warranty is 7 years or 70,000 miles. Engine is 7 years 100,000 miles. The full trans service had to be done at 45,000 (60,000 in manual) due to slipping in 5th. Complete fluid and filter changed made it work like new. I am changing fluid and filter while repairing leak and will change every 30,000 miles from now on. This will include replacing the o-rings on the guide bushing for the electrical plug to trans. These o-rings ( .50 ea.) have failed twice before.
  • Trying to learn the ins & outs for doing a proper job at on the fuel filter replacement.
    Suggestions about a good after market fuel filter for the V6 CAD ?
    Bloody dealer chaps are demanding $200 for parts w/ labor.
    I know I must have a bit of "highlander" in me. But really now isn't this a bit over board for a fuel filter W/ labor?
    I really have to do this myself.
    Thanks for any do it yourself direction.
  • jftfijftfi Posts: 10
    Go to and purchase the filter for $36.00 ($98.00 list). This site is great for OEM parts and ships ASAP. I purchased the Ultimate Service CD on e-bay and it has everything you need to know. This CD is all factory manuals and includes a complete parts section like the dealers use.
  • Major thanks,
    I'm on it now.
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