Daimler Vans USA has discovered an issue affecting certain 2023 and 2024 Mercedes-Benz Sprinter models, including versions from the 1500 to the 4500 series. The problem stems from spring U-bolts supplied by Thun Automotive in Germany, which may not have met the required hardness specifications during manufacturing.
According to documents submitted to the National Highway Traffic Safety Administration (NHTSA), these U-bolts may have missed the necessary hardness treatment process. Daimler Vans USA warns that faulty U-bolts could lead to a gradual shift in the rear axle, potentially compromising vehicle stability and handling.
Mercedes-Benz AG first detected a potential discrepancy in the bolting process in July 2023. This led to an investigation into the affected vehicles and the equipment used during production. The equipment itself showed no issues, and the exact cause of the deviation was not initially clear. As a result, the suspected U-bolts were sent back to Thun Automotive for further testing. By September 2023, Thun Automotive confirmed that the bolts had not undergone the required heat treatment process.
Further investigations continued through December 2023, which revealed that the faulty bolts originated from a single production batch. Mercedes-Benz then reviewed shipment records to identify which vehicles had been fitted with these compromised components. Due to the risk of the rear axle tilting under certain driving conditions, Daimler Vans USA issued a safety recall for 1,232 affected vehicles.
These vehicles were manufactured between May 11, 2023, and October 11, 2023. So far, Daimler Vans USA has reported no accidents or incidents related to this defect. Dealerships across the country have been instructed to replace the spring U-bolts on affected vehicles free of charge. Thun Automotive has since adjusted its manufacturing process, ensuring that U-bolts produced after October 12, 2023, no longer have this issue.
Owners of the affected vehicles can expect to receive recall notifications by mail starting September 6, 2024.
