2003 Mercedes Benz SL500 fuel system problems

Filed Mar 15, 2022 · Fuel system · GA

The 2003 SL500 with seemingly no instigating incident or event had the gas tank baffle come apart due to the poor and faulty design of this component. This baffle now is loose and floats on the gas in the gas tank, banging around when there is acceleration or deceleration, even turning sometimes causes it to bang around. Speed bumps are another source of loud banging from the baffle bumping into the sides of the tank. The issue with 2003 SL500's is ubiquitous, it is not a question of what percentage of them will experience as it appears it will happen to this vehicle at some point due to the poor design and implementation of the baffle. This wouldn't be such a big problem if this was a minor repair and was a reasonable price to have a shop perform or for the more mechanically inclined owner to perform themselves, but it is a ridiculously complex and time-consuming job just to get to the gas tank and take it off. My mechanic told me it is akin to taking the transmission or engine out and as such labor is outstandingly and outrageously expensive with this job requiring approximately $2000-$2500 to perform according to my mechanic and other SL500 owners who have also had to deal with this issue. This is an issue that you may not experience if you don't own one of these vehicles for long enough, but the vehicle will have this problem during it's lifetime and Mercedes should be responsible for allowing such a design to make it into production.

Filed Jul 6, 2020 · Fuel system · 87,500 miles · NJ

Hearing clanging, thump noise between seats and truck, took it to a repair shop and was advised it is a common issue with this model - problem with baffle in the tank and might have come off, searched on-line and found hundreds of complaints for the same issue, was this ever addressed by mb and recalled?

Filed Dec 19, 2016 · Engine, Fuel system · 55,620 miles · CA · fire

Tl* the contact owns a 2003 mercedes-benz sl500. While driving into the garage, the abc pump warning indicator illuminated and the contact noticed smoke inside the vehicle. In addition, the contact noticed a large amount of hydraulic fluid on the garage floor. The vehicle was towed to a dealer where it was diagnosed that the front and rear axle valve lock, and pressure reservoir for the abc system needed to be repaired and flushed. The vehicle was not repaired. The VIN was not included in the federal safety agency campaign number: 07v263000 (suspension, engine and engine cooling). The manufacturer was made aware of the failure. The approximate failure mileage was 55,620.

Filed May 16, 2016 · Fuel system · 52,000 miles · WA

Here a banging noise behind the seat, took it to a mercedes benz repair shop. They informed me the fuel tank baffle is broken free. He said it is very common on this model. But not covered under warranty or recall. It would cont me over 2,500.00 to repair. Doing some research online at mbworld forum. This happen on almost every car like this. I can not afford to fix this. And I am worried this might blow up or something, since something banging around the the inside of the fuel tank can not be safe, this car runs on premium gasoline. It seems to happen louder when the tank is from 3/4 full to 1/2. If I let it run to low the fuel gauge sticks on empty until I go over a big bump. I believe this is a factory defect as the car only has 60,000 miles on it. I should not have to replace the fuel tank on a car that cost about 100,000.00 new. But more important, I do not feel this car is safe to drive in this condition. The dealer stated it is not a safety issue, just an annoyance???

Filed Oct 23, 2015 · Fuel system · 56,408 miles · FL

Tl* the contact owns a 2003 mercedes benz sl500. While driving at various speeds, an abnormal noise could be heard in the vehicle. The vehicle was taken to an independent mechanic where it was diagnosed that the baffle in the fuel take fractured and needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was approximately 56,408.

Filed Feb 15, 2015 · Engine, Fuel system · 114,121 miles · CA

Driving along on 2/14/2015, I hear a banging coming from the back of the car. I notice it only does it when I am excelling or braking. I thought there may be something in the trunk, like a liquid with something floating in it, banging up against the side of the container. After I parked, I checked out the box that I have put in the back of my car. There was nothing there that would make this noise. Upon further investigation, I see that there many complaints against the baffle that is inside the gas tank that comes lose and bangs the sides of the gas tank. This is not acceptable. I will take my car to the shop on tuesday and see about repairs and having mb pay for it.

Filed Sep 7, 2014 · Fuel system · 35,000 miles · UT

I filed this complaint months ago and haven't heard a word. The issue is the gas tank baffle has apparently come loose from inside the tank and is creating a bang in the tank vehicle is slowing down and stopping. There was no accident. Mercedes said they haven't heard of this problem but in research this is a problem with 2003-2004 sl500. Is there a safety problem with this baffle being loose in the tank? And why isn't there a recall?

Filed Sep 5, 2014 · Fuel system · 42,000 miles · MS

Baffle in fuel tank started hitting the side of the tank make a noise when fuel tank is 3/4 full or less. Apparently the baffle breaks at one end allowing the baffle to bang against the wall of the fuel cell.

Filed May 16, 2014 · Body, Fuel system · 74,000 miles · CA

I own a 2003 mercedes benz sl500. Like most owners of this vehicle, the baffle moves freely within the gas tank which causes a noise and is potential dangerous if a spark is created from the baffle hitting the inside walls of the gas tank. From my research it is a manufacture issue with the welding of the baffle to the internal wall of the gas tank. There is a tremendous amount of complaints and threads on mercedes forums. Please follow link to see all complaints. It is poor customer service and accountability from mercedes benz USA to not recall the issue. There is over 20 pages of complaints regarding this issue at this link: http://www.benzworld.org/forums/r230-sl-class/1295215-sl500-noise-rear-interior-wall-gas.html.

Filed Oct 24, 2013 · Fuel system · 41,000 miles · UT

The baffle inside the gas tank has come loose and is hitting the inside of the tank. The only time it isn't noisy is when the tank is full. After contacting mercedes of utah, they advised they haven't heard of the problem. I don't know if there is a safety issue with the baffle being loose but it is a great concern to me.