The Rear Axle Drivetrain Assembly failed. Specifically, a critical structural fastener (bolt) associated with NHTSA Recall #25V090 (MBUSA #2025020010) completely detached from the rear axle. The vehicle is currently in my possession and the failed component/repair is photographed. The detachment of this structural bolt caused a complete loss of propulsion while the vehicle was in a commercial driveway. Had this occurred minutes earlier during my 500-mile round trip on the I-95 highway, it would have resulted in a catastrophic drivetrain separation or axle lock-up at highway speeds (65+ mph). This posed a fatal risk to myself, my passengers, and other motorists. The failure was confirmed and documented by an independent service center (Crown Auto, [XXX] ) and subsequently confirmed by an authorized Mercedes-Benz dealer (Mercedes-Benz of White Plains). White Plains issued a strict Do Not Drive order and dispatched emergency roadside assistance to transport the vehicle. The vehicle has been inspected by Mercedes-Benz of White Plains (authorized manufacturer representative) and Crown Auto. I have photographic evidence of the failed component prior to the re-repair. Mercedes-Benz of El Cajon (the originating dealer) has also been provided with photographic evidence but has refused to acknowledge the failure. No warning lamps or messages appeared prior to the failure. The first symptom was a complete loss of propulsion and a spinning sensation from the rear axle upon arriving in Queens. This lack of warning is particularly dangerous as the vehicle gave no indication of the impending structural failure during a 500-mile highway journey. The Service Director at the originating dealership, Ernie Serrano, initially denied the existence of the safety recall in writing and subsequently suggested that I misrepresent the nature of the failure to avoid a 'failed recall' record. This suggests a systemic attempt to hide safety-critical repair failures from the manufacturer a INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INF

The contact owns a 2024 Mercedes-Benz E Sprinter. The contact stated that while driving at 10 MPH, there was an abnormally loud sound coming from the passenger’s side of the vehicle. Several unknown warning lights were illuminated. The contact pulled over to the right side of the road and turned off the vehicle for an hour. The vehicle was then restarted and worked as intended; however, after the vehicle was parked in a public parking lot, several undisclosed electrical failures occurred. A dealer was contacted. The vehicle was towed to the dealer, and it was determined that the A-frame needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure, and referred the contact to the NHTSA Hotline to report the failure. The approximate failure mileage was 22,000.

Vehicle not starting after DC charging Complaint Vehicle will not start after DC charging Warning in the instrument cluster related to High-voltage on board electrical system The following fault codes related to stuck contactor can be found in the High Voltage Control units : PTCU - N127 (Powertrain control unit) • P154900 - There is a warning due to overcurrent in the charging system of the high-voltage electric circuit. • P154A00 - There is a warning due to a detected crash event at standstill. • P154B00 - There is a warning due to a stuck contactor. DCB223 - N116/5 (Direct current charge connection unit) • P0E8929 - The input current of the on-board DC charging connection unit is too high. There is an invalid signal. • P2BC500 - The contact ''Positive terminal'' of the contactor in the on-board DC current charge-connection unit is jammed closed • P2BCC00 - The contact ''Negative terminal'' of the contactor in the on-board DC current charge-connection unit is jammed closed. Remedy • Check for a new software availability for DCCU (N24/6 - Direct Current Charge connection Unit). If a new software is available, update the software first. • Reset contactor fault through special procedure without password. ( N24/6 >> Special Procedure >> Resetting of contactor fault.)

Check engine light with reduced power with fault codes P300A6D, P300974, P300DFB, or P300DE8 Complaint: The check engine light is activated, accompanied by one or more of the following fault codes related to the Boost Pressure Positioner: • P300A6D The boost pressure is too low. Charge Air Cooler. • P300974 Component 'Boost pressure positioner' has a malfunction. The boost pressure is too low. • P300DFB Component 'Boost pressure positioner' has a malfunction. • P300DE8 Boost pressure control A has a malfunction after the cold start. Cause: The potential causes for these fault codes are: A. Leak or Blockage in the Intake or Charge Air System: This can prevent the proper flow of air,  affecting the boost pressure. B. Insufficient Source Vacuum, Vacuum Leak, or Sticking/Weak Vacuum Component: These issues can  prevent the boost pressure positioner from functioning correctly. C. Internal Malfunction of the Boost Pressure Positioner: The component itself may be faulty. D. Internal Defect with the Variable Turbine Geometry (VTG) System inside the Turbocharger: Issues  within the turbo-charger can affect boost pressure control. 

Low Coolant Warning, Potential Misfire, and Absence of External Coolant Leaks Complaint Low Coolant warning with possible engine misfire caused by a leaking Charge Air Cooler  (Intercooler), accompanied by one or more of the following possible fault codes related to the  coolant system: P30040B: Component 'Temperature sensor downstream of charge air cooler' has an open circuit or  short circuit to po- sitive. P25567B: Sensor 'Coolant level' has a malfunction. The fluid level is too low. Cause The potential causes for this topic are: A. A leak in the Coolant System, other than the Charge Air Cooler. B. An Internal leak of the Charge Air Cooler. C. An unapproved/aftermarket upfit or modification to the coolant system. Remedy A. A leak in the Coolant System, other than the Charge Air Cooler 1. Complete a coolant system pressure test: •Refer to WIS Doc AR20.00-D-1011TS - Check engine cooling system for leak tightness. •Use Tester Cap 210 589 00 91 and Pressure Pump 124 589 24 21 00. •Apply test pressure to the engine cooling system. Do not exceed the specified test pressure of 1.5  Bar to prevent da- mage to the engine cooling system. •Perform a visual check on the top and bottom of the engine compartment and in the vehicle  interior. •If coolant loss or pressure loss is present, perform suitable repair measures depending on the  vehicle equipment. •If NO signs of coolant loss are found but pressure loss is present, proceed to Step B. 

Check engine light with possible Adblue warning with fault code P20F409 or P202E84 Complaint The check engine light is activated, accompanied by one or more of the following fault codes  related to the Adblue System: •P20F409: The Adblue consumption is too low. There is a component fault. •P202E84: The Adblue metering valve 1 (Motor side) has a malfunction. There is a signal below the  permissible limit value. Cause The potential causes for these fault codes are: A. A leak in the Adblue System B. An internal fault with the Adblue Injection Valve #1 (Motor side) C. An air pocket forming in the Adblue Injection Valve #1 (Motor side) Adblue Injector Line Remedy --Prior To Production Date 08/01/2024-- A. A Leak in the Adblue System 1. Complete the Guided Tests for P20F409 or P202E84: •Perform a thorough inspection of the Adblue Tank, the Adblue Pump, the Adblue Line, and both  Adblue Injectors for leaks. •Ensure the Adblue line is properly installed, securely fastened in all clips, and not in contact  with the exhaust system. •Remove both Adblue Injection Valves and complete 2-3 pressure build-ups and inspect for Adblue  leakage. •If a leak is identified, repair it and retest. 

Mercedes-Benz AG, the manufacturer of Mercedes-Benz eSprinter vans, has determined that a new NACS adapter informational label is required for the use of an approved Mercedes-Benz DC Fast Charging Adapter. An authorized Mercedes-Benz Sprinter dealer will affix the information label in the area of the charging socket.

Complaint: Noises when reversing slowly <5 km/h (squeaking) Cause: There is a seal in the electric drivetrain that seals off the coolant system from the electric motor. This seal is moistened with coolant during forward travel. As a result of the change in rotational direction when reversing slowly, it may be the case that this sealing ring is no longer moistened. Squeaking noises may occur as a result of the so-called stick-slip effect. This behavior does not impact the function or durability of the sealing ring and electric drivetrain. Remedy: Do not replace any parts. Explain the cause of the noises to the customer.

Complaint Check engine warning light active. Fault code P300CA8 or P300CA9 Hot film mass air flow sensor malfunction present in engine control  unit. Cause These faults can be set if: 1. A leakage upstream of the exhaust gas turbocharger causing a to high EGR rate. 2. Carbonized parts, e.g., the intake module, housing intermediate flange on high-pressure EGR valve (assembly of exhaust pressure sensor P3) or the intake ports also let through too little air. 3. The air filter has been highly soiled, incorrectly positioned or has a deformation.

Complaint • Unable to calibrate battery, see Operator’s Manual. • Calibrate battery to ensure max. range is achieved, start charging process up to 100%. Remedy: Standard calibration is necessary. • Calibrate battery to ensure max. range is achieved, charging time extension: start XX min AC charging up to 100%. Remedy: Special calibration is necessary. • Battery calibration necessary, start AC charging up to 100% for state of charge: max. 15%; outside temperature: min. 15 °C. Remedy: Special calibration is necessary. Cause The eSprinter 2.0 (model series 907) is equipped with a high-voltage battery with LFP (lithium iron phosphate) technology. This stands out in comparison to the NMC technology (lithium nickel manganese cobalt oxide) through its particularly long service life but it has to be calibrated regularly to achieve a precise SOC and range forecast. Ideally, along with the automatic calibration, a special calibration should also be conducted 2 times a year. Remedy Automatic/standard calibration of high-voltage battery Conducted automatically during every charging process up to 100% and it does not need to be triggered. Requirements for special and manual calibration: • The driver can wait for the calibration-related extended charging time to be completed. • The outside temperature is at least 15 °C. • The state of charge is less than 15%. • High-voltage battery charged up to 100%. • With automatic calibration the high-voltage battery has to be charged with AC. With manual calibration, DC charging is also an option. • Check if a departure time is preset that is reached before the end of the charging time (including charging time extension) and, where possible, deactivate it. • Check if the maximum state of charge is set to 100%. • Check if, during calibration, an electrical consumer was used or if the power supply was switched on. • Where possible, avoid any strong cooling of the vehicle or re-arrange the time of the calibration until the weather conditions are more favorable.

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