The car was in slow driving condition in hot weather driving.. The heater fan motor and/or heater fan wiring at the motor overheated and burned all plastic surrounding the plastic connector and wiring near it. The fire then spread to surrounding plastic heater blower fan housing and extinguished when heater hose burned and burst/sprayed sending antifreeze to put out the fire. The fire source was easily identified as the fire was localized in the wiring connector to the fan motor connector area and no other part of the underhood fire. The correct amperage fuse is in place for the affected circuits powering the fan motor. The factory is investigating the source of the fire. I have several pictures of the fire damage.
The worst 2005 Dodge Sprinter 3500 problems
Ranked by number of owner complaints. Mileage and cost come from what owners wrote.
- Engine4
- Transmission2
- Electrical1
- Fuel system1
Problems by type
Tap a problem to see which part fails, at what mileage and in which other years.
- Engine4
- Transmission2
- Electrical1
- Fuel system1
Recalls 2
Electrical system: instrument cluster/panel
- What is wrong
- Daimler Vans USA, LLC (DVUSA) is recalling certain model year 2003-2006 Dodge and Freightliner Sprinter 2500 and 3500 vans manufactured June 30, 2003, to August 31, 2006. The instrument cluster on the affected vehicles fails to illuminate the BRAKE warning lamp in the instrument cluster during the vehicle start up bulb-function check. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 105, "Hydraulic and Electric Brake Systems."
- Risk
- Without the BRAKE lamp illuminating during the vehicle start up bulb-function check, the driver has no confirmation that the lamp is working and therefore may not know whether or not the lamp will illuminate if the brake fluid level is low. If the operator is unaware that the vehicle has low brake fluid, there would be an increased risk of a crash.
- Remedy
- DVUSA will notify owners, and DVUSA and Dodge dealers will correct the instrument cluster software, as necessary, free of charge. An interim notification was sent to owners on January 6, 2017. A second notice will be mailed to owners once the remedy becomes available. The recall began on July 27, 2017. Owners may contact DVUSA customer service at 1‑770‑705‑2070.
Recall number 16V833000 · Recall details
Steering: column
- What is wrong
- Sprinter is recalling 10 my 2001-2006 dodge and freightliner 2500 and 3500 vehicles. The welding seam between the bracket and steering column of affected spare parts does not meet design specifications. The result of an out of specification welding seam is that the steering column may detach from its interior vehicle mounting bracket.
- Risk
- The operator may lose steering ability of the vehicle increasing the risk of a crash.
- Remedy
- Dealers will inspect and replace the steering columns free of charge. The recall is expected to begin on or before february 16, 2009. Owners may contact sprinter at 843‑695‑5057.
Recall number 08V339000 · Recall details
Technical service bulletins for the 2005 Dodge Sprinter 3500 3
Bulletins tell dealers how to fix known problems. A warranty extension means the manufacturer pays for that repair for longer.
What 2005 Dodge Sprinter 3500 owners say
Most recent owner complaints, unedited.
Our turbo resonator failed four times. Every time this happened we were driving on the highway at 60 MPH and then suddenly no power and our vehicle went into limp mode and our maximum speed was 30 to 35 MPH. Very, very dangerous situation. When this happened to us the 4th time I researched this on line and it looks like late 2004, 2005, 2006 and 2007 models are all equipped with the 2.7 liter 5 cylinder in line turbo diesel. The resonator is made of a plastic bonded together assembly and is not well suited for high heat, vibration and high pressure environment so it splits and puts the vehicle and occupants in great danger . According to the article I read this has happened to many sprint owners and that there is an easy fix. I strongly feel there should be a recall on this part. I have reached out to the dodge corporate office and to timothy kuniski by letter asking why there was not a recall on this resonator. Dates that resonator had to be replaced:6/30/2008, 6/20/2011, 7/15/14 10/8/2015. Please note that the first time we replaced the resonator our mileage was 37,722, the second time we replaced the resonator our mileage was 60,433, the third time mileage was 93,424 and the fourth time was 97,267 status updated 11/15/16.*jb updated 12/29/16.*jb updated 03/08/17.*jb the consumer requested an update. Updated 03/21/2017
June 14, 2009 the federal safety agency: for the 4th time our winnebago dodge sprinter/rv has lost power due to parts failure [turbo resonators, sensors, and/or turbocharger]. Needless to say these failures took place while many miles from home and away from anyone who could help. When certain parts fail, the sprinter is designed to enter a "limp home" mode at a greatly reduced speed, thus endangering us as we were traveling on busy highways, fearful we would be rear ended by a truck or other heavy vehicles. In addition to imperiling our lives, we have endured extra expense and great inconvenience for delayed and canceled trips resulting from these breakdowns. Judging from forums online recently, this is a problem that is quite common and daimler chrysler is well aware of it, but, by inaction, has failed to remedy. Dealers replaced the parts with the same flimsy plastic defective parts, which is not satisfactory as they will inevitably fail again. A recall is certainly justified. George and barbara dematteis cc: daimler chrysler motors corp. Winnebago industries ed voyles chrysler congressman lynn westmoreland.
Driving on us hwy 2 up stevens pass, washington at 50 MPH when engine power began cycling, black smoke came out of exhaust, rapidly lost power and max speed dropped to 30mph with accelerator to floor. Quickly began blocking traffic and had to pull over to let vehicles by. Turned around and headed back home. Took van to dealership and they had to replace turbo resonator (2nd time in 5000 miles).
Vehicle lost power while climbing a hill on a 2 lane highway. Max vehicle speed dropped to 25mph on 55mph road - nearly rear-ended by vehicle behind. Had to drive over 150 miles home at slow speeds to get to dealership for repair. Dealership replaced turbo resonator.
Failed turbo resonator going to yosemite in itaska mh with dodge 5 cyl diesel engine. This is second turbo resonator to fail and is extremely dangerous condition on 2 lane rds with few turnouts and steep banks. Dodge should recall resonators and replace with available aftermarket item. Numerous failures in rv's.
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Questions about the 2005 Dodge Sprinter 3500
Is the 2005 Dodge Sprinter 3500 reliable?
Owners have filed 6 complaints about the 2005 Dodge Sprinter 3500, close to a typical Sprinter 3500 model year.
What is the most common problem with the 2005 Dodge Sprinter 3500?
Engine and cooling, with 4 complaints. Next is transmission (2).
How many recalls does the 2005 Dodge Sprinter 3500 have?
2 recalls, covering electrical system and steering.
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