NHTSA vehicle safety data

2005 Dodge Sprinter 3500 Recalls & Complaints

The 2005 Dodge Sprinter 3500 has 2 NHTSA recall campaigns and 6 owner complaints on file as of November 3, 2026. Recall repairs are usually free at an authorized Dodge dealer.

NHTSA recall and complaint data for the 2005 Dodge Sprinter 3500. Recall data is refreshed daily from NHTSA.

2005 Dodge Sprinter 3500 owner complaints

Owners have filed 6 complaints with NHTSA about the 2005 Dodge Sprinter 3500, describing incidents dated September 13, 2006 to August 12, 2020.

Most-cited components

Engine 4 complaints
Power Train 2 complaints
Electrical System 1 complaint
Fuel/Propulsion System 1 complaint

Of the 6 complaints on file, 1 reports a fire (owner-reported, not verified by NHTSA).

Newest complaints

ODI #11350672 · Filed August 21, 2020
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…
ODI #10870006 · Filed May 20, 2016
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…
ODI #10273733 · Filed June 14, 2009
JUNE 14, 2009 NHTSA: 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…

Read all 6 complaints

BRAKE Indicator Lamp Inoperative/FMVSS 105

NHTSA #16V833000 · Electrical System — Instrument Cluster/Panel · NHTSA notice

Reported November 17, 2016 · Daimler Vans USA, LLC

Potentially affected: 17,501 vehicles

Repair completion: 17.24% (latest rate the manufacturer reported to NHTSA; dataset updated November 3, 2026)

Owners notified July 27, 2017 · Vehicles built June 30, 2003 – August 31, 2006 (per NHTSA)

Defect description

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."

Safety consequence

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.

Manufacturer 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.

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

STEERING COLUMNS

NHTSA #08V339000 · Steering — Column · NHTSA notice

Reported July 24, 2008 · SPRINTER ENGINEERING & COMPLIANCE SUPPOR

Potentially affected: 10 vehicles

Manufacturer campaign H25 · Owners notified February 16, 2009 · Vehicles built November 1, 2007 – November 30, 2007 (per NHTSA)

Defect description

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.

Safety consequence

THE OPERATOR MAY LOSE STEERING ABILITY OF THE VEHICLE INCREASING THE RISK OF A CRASH.

Manufacturer 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.

Notes

CHRYSLER'S RECALL NO. H25.CUSTOMERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO HTTP://WWW.SAFERCAR.GOV.

try.vin has no NCAP crash-test rating on file for the 2005 Dodge Sprinter 3500. NHTSA rates some vehicles by body style — pickups by cab, vans by roof height — so check nhtsa.gov/ratings.

6 owner complaints have been filed with NHTSA for the 2005 Dodge Sprinter 3500.

Electrical System

ODI #11350672

Fire

Incident: August 12, 2020 · Filed: August 21, 2020

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.

Engine and Engine Cooling; Power Train

ODI #10870006

Incident: June 30, 2008 · Filed: May 20, 2016

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 *JS

Power Train

ODI #10273733

Incident: June 11, 2009 · Filed: June 14, 2009

JUNE 14, 2009 NHTSA: 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. *TR

Engine and Engine Cooling

ODI #10269077

Incident: May 15, 2009 · Filed: May 18, 2009

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). *TR

Engine and Engine Cooling

ODI #10269072

Incident: September 13, 2006 · Filed: May 18, 2009

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. *TR

Engine and Engine Cooling; Fuel System, Diesel

ODI #10229458

Incident: May 12, 2008 · Filed: June 1, 2008

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. *TR

Other Dodge Sprinter 3500 model years

Check your 2005 Dodge Sprinter 3500 VIN

Not every recall applies to every VIN in a given year. Enter the 17-character VIN from your Dodge Sprinter 3500 at nhtsa.gov/recalls to see whether your specific vehicle has an unrepaired recall.

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