2004 Dodge Sprinter
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
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Vehicles › Dodge › Sprinter › 2004
These records cover every 2004 Dodge Sprinter. To see whether one car still needs a recall repair, decode its VIN or check it with NHTSA.
Owner complaints
39 complaints1 involved a fire
What owners report most
Latest complaints
- Fuel/propulsion system
Upon completion of the T21 recall, the check engine light (error code u0423) came on. The instrument cluster light continued to illuminate after the vehicle's ignition was off, draining the battery.
- Engine
TL* the contact owns a 2004 dodge sprinter. The contact stated that the vehicle consistently misfired. The dodge manufacturer included the vehicle in its T21 emissions recall for the engine control unit; however, the tools, an available technician, and the part was not available to schedule the…
TL* the contact owns a 2004 dodge sprinter. The contact stated that the vehicle consistently misfired. The dodge manufacturer included the vehicle in its T21 emissions recall for the engine control unit; however, the tools, an available technician, and the part was not available to schedule the repair appointment. The following dealers were contacted: ed voyles chrysler dodge jeep RAM (789 cobb pkwy SE, marietta, ga 30060, (844) 715-5921), shottenkirk chrysler dodge jeep RAM (200 liberty blvd, canton, ga 30114, (678) 535-3417), landmark dodge chrysler jeep RAM (6850 mt zion blvd, morrow, ga 30260, (770) 968-4900), don jackson chrysler dodge jeep RAM (3950 jonesboro rd, union city, ga 30291, (770) 969-7229), and mall of georgia chrysler dodge jeep (4345 buford dr, buford, ga 30518, (888) 522-5112). The vehicle was not diagnosed and was not being driven due to the failure. The manufacturer was notified of the failure and assigned a case manager who was to respond within one business day. The contact was waiting for a response from the manufacturer. The failure mileage was not available. *tt consumer stated today IS august 10,2018 and we are still attempting to resolve our recall T-21 of sprinter 2004. Although it has taken 3 month to even attempt to get this recall resolved. we went ti have the situation solved on aug 7. Now after a service manager asked his own personal computer to do the update... We now have a "check engine" light on- still not resolved many poor excuses from cia- case# 3646736668. updated 10/9/18*jb
- Unknown or other
I used your online vin checker to see if my car has a recall and it said no recalls, and request invalid but I know I entered the correct vin and you gave me my vehicle year and model information.
- Tires
Four p225/75r15xl scorpion str tires purchased & installed 8-5-10 at evans tire &service center 1530 garnet ave. San diego ca 92109 onto 2004 dodge sprinter 2500, mileage 28274. on 2-28-2015 mileage approx.43125mi. : passerby reported left rear tire appeared very low on air; driver…
Four p225/75r15xl scorpion str tires purchased & installed 8-5-10 at evans tire &service center 1530 garnet ave. San diego ca 92109 onto 2004 dodge sprinter 2500, mileage 28274. on 2-28-2015 mileage approx.43125mi. : passerby reported left rear tire appeared very low on air; driver immediately presentedvan to same shop where employee refused to fill adjust air pressure due to his reporting evident sidewall cracks & his fear of tire exploding. he offered to sell new tires. Calling same shop today for tire options & price quotes another employee referred/ connected call to their evans tire center for tire options & prices, where yet another employee offered to sell new capital ( sp. Capitol?)tires, quoting price described as"....at their (evans' )cost..." please respond and relay a copy of this complaint to all appropriate federal and california state consumer and auto repair, tire sale regulatory &licensing agencies . Thank you. *tr
- Structure › Body
The sliding door which IS the only egress for passengers in the back of the van will not open. I have had it fixed 4 times and it continuously fails. I have talked to other sprinter owners and they have the same problem. should there be an incident that required the quick evacuation of the van…
The sliding door which IS the only egress for passengers in the back of the van will not open. I have had it fixed 4 times and it continuously fails. I have talked to other sprinter owners and they have the same problem. should there be an incident that required the quick evacuation of the van by passengers in the rear of the van they could be very seriously harmed. this IS a very serious defect that chrysler will not acknowledge. *tr
- Engine
Driving at freeway speed the vehicle losses power and the speed decreases to about 40 mph. I can pull over and turn of the motor for about 10 seconds and start up and the vehicle will reset and run fine until it does it again randomly. This IS very dangerous especially when you are in the left…
Driving at freeway speed the vehicle losses power and the speed decreases to about 40 mph. I can pull over and turn of the motor for about 10 seconds and start up and the vehicle will reset and run fine until it does it again randomly. This IS very dangerous especially when you are in the left hand lane and you are trying to get to a safe place to pull over. This has happened several times and I have replaced the turbo resonator 3 time on this truck. This IS a plastic part and the body cracks from the vibration and pressure. *Tr
- Service brakes, hydraulic
2004 dodge sprinter - the braking system stiffens up (power brake) if I push the pedal hard especially when I back up the vehicle. It's like the booster has frozen solid and the brake pedal can't travel all the way down. If I let the vehicle sit for a while (1 hr) it will get back to normal. This…
2004 dodge sprinter - the braking system stiffens up (power brake) if I push the pedal hard especially when I back up the vehicle. It's like the booster has frozen solid and the brake pedal can't travel all the way down. If I let the vehicle sit for a while (1 hr) it will get back to normal. This IS a repeat incident and started in the first year but I did not pay too much attention since I did not understand what happened and the problem disappeared for a while. but lately IS reappearing more frequently. No accident yet. Nothing has been done to correct the failure. The vehicle IS out of warranty by now 66,000 miles. I wonder if there are more people experiencing the same. *Tr
- Equipment · Power train › Automatic transmission · Structure › Body
In may of 2005 I purchased a new dodge (mercedes benz) sprinter 2500 passenger van. Within the first 3 months and 7,500 miles of date of purchase the vehicle began to show signs of premature rusting and leakage over the entire vehicle. I pursued remedy thru all authorized sprinter dealerships…
In may of 2005 I purchased a new dodge (mercedes benz) sprinter 2500 passenger van. Within the first 3 months and 7,500 miles of date of purchase the vehicle began to show signs of premature rusting and leakage over the entire vehicle. I pursued remedy thru all authorized sprinter dealerships adhering to chrysler protocols and recommendations. No remedy was ever forthcoming, I repeatedly and continue to challenge chrysler, their refusal to provide warranty service for the entire time I have owed this vehicle IS documented and too extensive to provide here. I have filed bbb complaints in denver co. I have spoken to executive level chrysler customer service reps. And none have offered a viable solution. They have essentially washed their hands of a problem that I have been pursuing for 4 years. I have brought this issue to the attention of so many chrysler customer service people that they now avoid my emails and inquiries. I believe this to be a recall issue as I have found numerous references on the net to similar issues. The affected vehicles all show sign of premature rust ,leakage of roof seams and rust penetration around the windshield frame. I have sought repairs well within the rust thru warranty period and have met with nothing but lip service. Chrysler refuses to address a very serious issue and has delayed offering a remedy until now the warranty period has expired. I can provide explicit work orders and customer service ref no, within chryslers system. I am now considering pursuing legal options but little resolution IS available. Body shops refuse to perform repair work because they universally state that rust IS a nonfixable issue. On only one occasion did chrysler authorize a superficial attempt to paint over problem, they then refused to honor their rust thru perforation warranty when the problem resurfaced with 35,000 miles. I am now left with a vehicle that IS rusting extensively in areas where I originally documented the problem. *Tr
- Electrical system · Interior lighting
There IS a safety recall ID # 07v299000 - interior lighting on the make and model of my vehicle and my vehicle has the same symptoms yet IS not part of the recall. Dodge has ordered the parts to be replaced and IS charging $277.67. Please let me know how to correct this issue. *Tr
- Wheels
Original equipment steel wheel on 2004 dodge sprinter broke along "spokes". this could be a life threatening condition at highway speeds or in a loaded van. I noticed a noise coming from the wheel and took it to a shop where they could find nothing wrong because the cracks in the wheel are very…
Original equipment steel wheel on 2004 dodge sprinter broke along "spokes". this could be a life threatening condition at highway speeds or in a loaded van. I noticed a noise coming from the wheel and took it to a shop where they could find nothing wrong because the cracks in the wheel are very difficult to detect unless inspected very closely. the wheel that failed was never abused or mistreated in any way prior to failure. I still have the broken wheel if you wish to inspect it. I am now running on the spare. should I replace all 4 wheels on this van? will the others also fail? are all 2004 sprinter wheels this dangerous? *Tr
- Exterior lighting › Brake lights · Power train › Automatic transmission
Tl*the contact owns a 2004 dodge sprinter. within two months of purchasing the vehicle, the rear brake lights failed. the contact had to constantly take the vehicle to the dealer for repair. the manufacturer was notified, but there was no resolution. a blown tail light fuse was repaired, but it…
Tl*the contact owns a 2004 dodge sprinter. within two months of purchasing the vehicle, the rear brake lights failed. the contact had to constantly take the vehicle to the dealer for repair. the manufacturer was notified, but there was no resolution. a blown tail light fuse was repaired, but it continues to fail. the manufacturer has not sent the parts for the lights to be repaired. the failure mileage was unknown. updated 03-06-09 *bf the consumer also stated the transmision was not performing as it should. Updated 03/12/09
- Power train › Automatic transmission
Tl*the contact owns a 2004 dodge sprinter. the contact discovered oil on his driveway. the vehicle was taken to a dealer and they stated that there was a leaking plug on the transmission that released the oil onto the driveway. the current mileage was 17,000 and failure mileage was 15,000.
- Power train › Automatic transmission
Tl*the contact owns a 2004 dodge sprinter. the contact discovered oil on his driveway. the vehicle was taken to a dealer and they stated that there was a leaking plug on the transmission that released the oil onto the driveway. the current mileage was 52,000 and failure mileage was 35,000.
- Engine and engine cooling › Engine
While traveling on I-70 from frederick to cumberland in 2004 dodge sprinter pleasure-way rv, noticed a revving in the engine. going up first steep mountain, the engine dropped 10 mph from 65 to 55. drove through hagerstown and got on I-68 to cumberland. going up that mountain, the rv lost power…
While traveling on I-70 from frederick to cumberland in 2004 dodge sprinter pleasure-way rv, noticed a revving in the engine. going up first steep mountain, the engine dropped 10 mph from 65 to 55. drove through hagerstown and got on I-68 to cumberland. going up that mountain, the rv lost power in every gear and went into "limp home" mode. pulled off the highway and called tow truck. took to sprinter repair shop who knew exactly what the problem was - turbo resonator. took approximately .7 of an hour to replace with a new part. this should be a recall. in researching the issue - this has happened to many people. it IS not safe to be climbing mountains with tractor trailer and vehicle traffic and have this happen. *tr
- Tires › Pressure monitoring and regulating systems
There IS currently a complaint for the 2500 dodge sprinters, for valve stem failure. What about the 3500? I've had three valve stem failures so far and no recourse. Why IS the 2500 different than the 3,500? Two happened on the highway and one just let go while parked. Luckily two were on the rear duals and I had the other tire to bear the weight. *tr
- Engine and engine cooling › Engine
Engine stalls intermittently, with or without a/c. Can happen at any time after start up and at any speed without warning. Sometimes can happen after vehicle goes over a bump (even small ones), during turns, moving off from a traffic light. This IS highly dangerous. Dealer did install kit to…
Engine stalls intermittently, with or without a/c. Can happen at any time after start up and at any speed without warning. Sometimes can happen after vehicle goes over a bump (even small ones), during turns, moving off from a traffic light. This IS highly dangerous. Dealer did install kit to prevent potential stalling due to operation of heavy duty rear a/c during turns (known problem) but no effect. Engine restarts without hesitation after ignition key IS switched off and then turned on. Dealer has carried out an extensive electrical check with no results and cannot duplicate event. *tr
- Engine and engine cooling › Engine › Gasoline › Turbo/supercharger
Tl*the contact owns a 2004 dodge sprinter. While driving 65 mph, the vehicle speed decreased dramatically. the engine warning light illuminated after the vehicle decreased in speed. he took the vehicle to the dealer on nine occasions and they replaced the erg valve, turbo manifold, and the turbo…
Tl*the contact owns a 2004 dodge sprinter. While driving 65 mph, the vehicle speed decreased dramatically. the engine warning light illuminated after the vehicle decreased in speed. he took the vehicle to the dealer on nine occasions and they replaced the erg valve, turbo manifold, and the turbo resonator. the contact stated that immediately after the repairs were made he experienced a similar failure. the failure mileage as 51,000 and current mileage was 78,000.
- Steering › Rack and pinion
Rack and pinion was replaced after leakage occured at 27000 miles. it IS leaking again but not covered under drive train warrenty and dodge refuses to replace it. However if this IS a reoccuring problem you should insist that dodge modify the design and effect a recall.
- Engine and engine cooling › Engine › Diesel
Fan pulley dislodges and tears up the front accessories. during extensive travels I have found dozens of sprinters having had the same problem. I think that the design or materials that make up the pulley are flawed and you should investigate. I further believe the descrepency based on conversations with mechanics IS well know to dodge yet IS also covered up by dodge.
- Engine and engine cooling › Engine
Tl*the contact owns a 2004 dodge sprinter. while driving 65 mph with cruise control activated, the vehicle shut down without warning. the contact pulled the vehicle over and it was towed to the dealer. the vehicle IS being diagnosed by the dealer at this time. the current and failure mileage were 72,000.*ak
- Tires › Valve
While parked in my driveway my 04 3500 dodge sprinter right rear outside tire suddenly deflated. The valve stem core had separated from the rubber, causing the tire to suddenly deflate. Dodge claims my truck IS not covered under the valve stem recall. This IS the 3RD. Valve stem to fail. *ak
- Tires › Valve
While parked in my driveway tires inflated to 60 psi maximum 65 psi, left front tire suddenly deflated. The valve stem core separated from the rubber causing the tire to deflate. the valve stem was replaced.this IS on a 04 3500 dodge sprinter and IS not covered under the valve stem recall according to dodge.*ak
- Tires › Valve
While parked in a store parking lot with tires inflated to 60 psi (max 65 psi) inside left rear tire on a 04 3500 dodge sprinter suddenly went flat, the valve stem core separated from the rubber causing the tire to lose air. *jb
- Visibility › Windshield
We own two dodge sprinters 2500. Years 2004 and 2006. we have owned both for a little more than a year. We have broken six winshields. We have looked for stronger windshields none are made.{ per ppg} we have had installs done by factory and private. The window fames have been inspected for…
We own two dodge sprinters 2500. Years 2004 and 2006. we have owned both for a little more than a year. We have broken six winshields. We have looked for stronger windshields none are made.{ per ppg} we have had installs done by factory and private. The window fames have been inspected for defects and none were found. We feel that this unacceptable and needs to be fixed. I have contacted dodge and they said that they will do an internal reviewbut we will not be notified. Currently this IS a great hazard and cost.
- Engine and engine cooling › Engine › Diesel
The crank shaft damper pully & r & r timing chain broke, rendering the vehicle immobile. parts were replaced and 2 months later, the same thing happened. *Jb
Defect investigations
NHTSA’s Office of Defects Investigation opened these reviews into vehicles including this one.
- Tire valve failure
Odi opened pe04-066 to investigate five complaints alleging tire valve failure in my 2003-04 subject vehicles.some of the complaints alleged multiple tire valve failures for a single vehicle.on december 16, 2004, daimlerchrysler manufacturing international (dcmi) notified nhtsa of a safety defect in approximately…
Odi opened pe04-066 to investigate five complaints alleging tire valve failure in my 2003-04 subject vehicles.some of the complaints alleged multiple tire valve failures for a single vehicle.on december 16, 2004, daimlerchrysler manufacturing international (dcmi) notified nhtsa of a safety defect in approximately 23,000 my 2002-05 sprinter 2500 vehicles equipped with tr-600 tire valves produced by alligator ventilfabrick gmbh (recall 04v-600).the notification identified the chemical specification of the rubber components and an unstable supplier production process, which resulted in inadequate mixing of the rubber components, as the factors contributing to this defect.as a result of these factors, cracks can develop within the rubber part or between the metal and the rubber parts of the valve stem, which can lead to a loss of air pressure at the valve stem and may pose a risk to motor vehicle safety.although the tr-600 tire valve IS used only on the 2500 series subject vehicles with 16 inch tires, dcmi will conduct a safety recall for all sprinter 2500 vehicles sold in the u.s. To replace the current tire valves with a tr-600 valve, which uses a single rubber component for the valves.all 24 complaints and all 43 warranty claims identified in this investigation involved my 2002-04 sprinter 2500 vehicles, which comprise approximately 84 percent of the subject vehicle population.
Service bulletins
Technical service bulletins and other communications the manufacturer sent dealers about this vehicle. Ask a dealer for the full document by its number.
- 10229256KEY, Master If replacing the key/FOBIK on a WJ, KJ, TJ, or PT Cruiser, use the "AC" NIC level part number. The "AB" NIC level will not program to these platforms. For all other platforms, if the "AB" NIC level will not program to the vehicle, use the "AC" NIC level part and submit a part warranty.
- 10229181Part Description: 5.7L Long Block Issue Description: This 5.7L Long Block Assembly is compatible with both EGR and Non-EGR applications. An EGR Block-Off Plate (53032739AA) must be ordered when installing this Long Block Assembly in a Non-EGR application. Unless, the EGR Block-Off Plate is being transferred from the old engine.
- 10223854Service - Four Piece Oil Pan Gasket All Cummins Equipped Vehicles ONLY - The replacement oil pan gasket can be a four piece gasket rather than a single piece gasket. This applies to Cummins 5.9L and 6.7L engines only. Installation: 1. Clean the oil pan T-joints.~ 2. Fill the T-joint between the pan rail/gear housing and pan rail/rear seal retainer with sealant. Use Mopar Silicone Rubber Adhesive Sealant or equivalent. 3. Apply a 2-mm [0.063-in] bead of Mopar Engine Sealant RTV Silicone Rubber Adhesive, to the oil pan flange.~ 4. The four piece gasket will need to be assembled to make a complete oil pan gasket. 5. Lay the oil pan gasket(s) onto the oil pan flange.~ 6. Ensure the oil pan gasket segment joints are properly aligned. 7. Apply a 2-mm [0.063-in] bead of Mopar Engine Sealant RTV Silicone Rubber Adhesive, to the top of the oil pan gasket.~ 8. Install the oil pan. Starting from the center and working outward, tighten the oil pan bolts to 28 Nm [21 ft. lbs.].
- 10223602Part Description: 5.7L Long Block Issue Description: This 5.7L Long Block Assembly is compatible with both EGR and Non-EGR applications. An EGR Block-Off Plate (53032739AA) must be ordered when installing this Long Block Assembly in a Non-EGR application. Unless, the EGR Block-Off Plate is being transferred from the old engine.
- 10221686KEY, Master If replacing the key/FOBIK on a WJ, KJ, TJ, or PT Cruiser, use the "AC" NIC level part number. The "AB" NIC level will not program to these platforms. For all other platforms, if the "AB" NIC level will not program to the vehicle, use the "AC" NIC level part and submit a part warranty.
- 10221319Emissions Recall T21 Reprogram Engine Control Unit
- 10220995Part Description: Insulator on Lever Assy Manual Valve - Valve Body - RWD Transmission Issue Description: The manual valve insulator, attaching rivet and instruction sheet are now available as a kit. If the insulator requires replacement please order kit 68253161AA. Insulator only used on Auto-RWD transmission Note: The color of the insulator is not relevant for service.
- 10220935Emissions Recall T21 Reprogram Engine Control Unit
- 10220101Use of Aftermarket Parts This bulletin involves discussing FCA US LLC position with regard to collision repair industry awareness regarding the use of aftermarket parts.
- 10220099Use of Salvage/Recycled Parts This bulletin involves discussing FCA US LLC position with regard to collision repair industry awareness regarding the use of recycled or salvage parts.
- 10220097Repair Parts Used For Structural Repairs This bulletin involves discussing FCA US LLC position with regard to structural repair parts usage.
- 10191460Valve Body. These may cause over drive cycling.
- 10176559Emissions Recall T21 Reprogram Engine Control Unit
- 10175743Disinfectant Solution Recommended for COVID-19
- 10175735Charging System, Battery Diagnostic Tools and Warranty This information only bulletin discusses using the correct test equipment for testing batteries and charging systems, and also warranty reimbursement when battery replacements are necessary.
- 10169249Use of Aftermarket Parts This bulletin involves discussing FCA US LLC position with regard to collision repair industry awareness regarding the use of aftermarket parts.
- 10169247Use of Salvage/Recycled Parts This bulletin involves discussing FCA US LLC position with regard to collision repair industry awareness regarding the use of recycled or salvage parts.
- 10169245Repair Parts Used For Structural Repairs This bulletin involves discussing FCA US LLC position with regard to structural repair parts usage.
- 1012900882212076, 82203694 - Fabric Cleaner This "fabric cleaner" is not intended for sale in California, the otc states (Connecticut, Delaware, Massachusetts, Maine, New Hampshire, New Jersey, New York, Pennsylvania, Virginia, and Washington dc), and some ladco states (Illinois, Michigan, and Ohio). Mopar offers an alternative product (82213192) which is a water based product approved for sale in the aforementioned states.~ ~ Please inform the customer & your prep dept that spraying excessive amounts of the fabric protector on load floors will result in the breaking down of the adhesive (glue) that is used to create the bond between the fabric (carpet) and the load floor. This will apply to any vehicles equipped with rear load floors such as WK, WD, PM, MK, KA, KK. The carpet will appear to be loose, wrinkly, or bunch up~
- 10021669Rear axle repair vs. Replace procedure change.
- 10021239Powertrain control module initialization.
- 10021170Bio-diesel B5 fuel.
- 10020083New crankshaft and center bolt design.
- 10019542Crankshaft replacement policy change and main bearing part number information.
- 10018684Turbocharger, change air cooler, and exhaust gas recirculation systems diagnosis on om647 engines.
- 10016603Air conditioning (a/c) cooling coil odor.
- 10013999Fuel system codes updated.
- 10013979Updated graphic for high pressure pump removal and installation.
- 10013731Powertrain control module initialization.
- 10013676Automatic transmission shifting concerns. 2001-2005 dodge sprinter.
- 10012339Transmission fluid may be wicking in the right front corner of the transmission oil pan area.
- 10010562Customer satisfaction notification D44 - egr valve. This could cause limited engine output and vehicle speed as well as illumination of the malfunction indicator lamp (mil). Also include the 2004 freightliner sprinter.
- 10010484Common rail fuel injection diagnosis. This bulletin supersedes bulletin 14-002-04, dated setpember 28, 2004.
- 10007924Ringing sound coming from propeller shaft when transmission IS shifted from drive to reverse or reverse to drive.
Every Dodge Sprinter model year
Bars are owner complaints, dots mark years with recalls. Select a year to open its report.