2005 Dodge Sprinter 3500 problems

Overview of popular issues
Analysis of common problems
Сomplaints list
Recalls list

Social links

Common 2005 Dodge Sprinter 3500 problems

Based on the complaints from owners of the 2005 Dodge Sprinter 3500, here are the common problems with this vehicle:

Limp Mode / Power Loss: The Sprinter may go into a "Limp Mode" to protect the engine from damage, especially when pushed to the limit. This mode is activated when the Check Engine Light flashes on the dashboard, reducing engine power to prevent further issues.

DEF Heater Failure: The Diesel Emission Fluid (DEF) heater is crucial for preventing the fluid from freezing. When this heater fails, it can trigger the engine warning light, particularly in colder months, leading to potential issues with the emission system.

Turbo Resonator Air Leak: The Turbo Resonator in the Sprinter Van is known for problematic seals and O-Rings, often causing air leaks that are sometimes mistaken for oil leaks. This issue can affect the turbo output and may require attention to prevent further complications.

These problems highlight some of the key issues faced by owners of the 2005 Dodge Sprinter 3500. Each problem requires specific attention and repair to ensure the vehicle's optimal performance and reliability.

What is the life expectancy of a 2005 Sprinter van?

When it comes to Mercedes-Benz Sprinter engine life, expect a fruitful timeline. Sprinter vans, with proper maintenance and best-driving practices, last anywhere from 250,000 to 300,000 miles.

Are Dodge Sprinter vans reliable?

Dodge Sprinter Reliability Problems

Sprinter owners have made 8 complaints over 6 model years. Using our PainRank™ system we've ranked it 5th in overall reliability out of 29 Dodge models , with some engine and electrical concerns.

How many miles can a Dodge Sprinter go?

Sprinter vans are known for their reliability and versatility, making them the most popular choice for van conversion. The Mercedes-Benz Sprinter is considered a dependable workhorse that runs on a diesel engine and it's very common for Sprinters to be going strong at 450,000+ miles.

Are Dodge Sprinters expensive to maintain?

The annual maintenance cost of a Dodge Sprinter 2500 is $1,165. Repair and maintenance costs vary depending on age, mileage, location and shop.

What is the life expectancy of a 2005 Sprinter van?

When it comes to Mercedes-Benz Sprinter engine life, expect a fruitful timeline. Sprinter vans, with proper maintenance and best-driving practices, last anywhere from 250,000 to 300,000 miles.

Are Dodge Sprinters expensive to maintain?

The annual maintenance cost of a Dodge Sprinter 2500 is $1,165. Repair and maintenance costs vary depending on age, mileage, location and shop.

Are Dodge Sprinter vans reliable?

Dodge Sprinter Reliability Problems

Sprinter owners have made 8 complaints over 6 model years. Using our PainRank™ system we've ranked it 5th in overall reliability out of 29 Dodge models , with some engine and electrical concerns.

Which year is the best Sprinter?

Which is the BEST Sprinter year

2004. Votes: 115 11.7%
2005. Votes: 148 15.0%
2006. Votes: 395 40.1%
2007. Votes: 71 7.2%
2008. Votes: 138 14.0%
2009. Votes: 29 2.9%
2010. Votes: 89 9.0%

2005 Dodge Sprinter 3500 car problems categorized by type of issue

After analyzing all complaints sent to the NHTSA and researching popular Dodge Sprinter 3500 problems, we found that the most common problems with these 2023 model year vehicles are:

Engine and engine cooling problems
Power train problems
Electrical system problems
Fuel system problems
Diesel problems

The graph below shows statistics for all 2005 Dodge Sprinter 3500 vehicle components and the number of complaints received.

2005 Dodge Sprinter 3500 complaints

The NHTSA has received 6 complaints about various vehicle components related to the 2005 Dodge Sprinter 3500.

2020-08-21

ELECTRICAL SYSTEM PROBLEM

Date Of Incident: 2020-08-12
Fire: 1
VIN: WD0PD544455
Components: ELECTRICAL SYSTEM
Summary: 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.

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2016-05-20

ENGINE AND ENGINE COOLING,POWER TRAIN PROBLEM

Date Of Incident: 2008-06-30
VIN: WDXPD944555
Components: ENGINE AND ENGINE COOLING,POWER TRAIN
Summary: 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

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2009-06-14

POWER TRAIN PROBLEM

Date Of Incident: 2009-06-11
VIN: WDXPD944355
Components: POWER TRAIN
Summary: 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

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2009-05-18

ENGINE AND ENGINE COOLING PROBLEM

Date Of Incident: 2006-09-13
VIN: WDXPD944X55
Components: ENGINE AND ENGINE COOLING
Summary: 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

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2009-05-18

ENGINE AND ENGINE COOLING PROBLEM

Date Of Incident: 2009-05-15
VIN: WDXPD944X55
Components: ENGINE AND ENGINE COOLING
Summary: 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

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2008-06-01

ENGINE AND ENGINE COOLING,FUEL SYSTEM, DIESEL PROBLEM

Date Of Incident: 2008-05-12
VIN: WDXPD944755
Components: ENGINE AND ENGINE COOLING,FUEL SYSTEM, DIESEL
Summary: 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

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2005 Dodge Sprinter 3500 recalls

The National Highway Traffic Safety Administration (NHTSA) has issued 2 recalls for different components of the 2005 Dodge Sprinter 3500.

2016-11-17

Manufacturer: Daimler Vans USA, LLC
Components: ELECTRICAL SYSTEM: INSTRUMENT CLUSTER/PANEL
Summary: 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."
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.
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.

2008-07-24

Manufacturer: SPRINTER ENGINEERING & COMPLIANCE SUPPOR
Components: STEERING:COLUMN
Summary: 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.
Consequence: 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.

Additional sources

More sources of information about 2005 Dodge Sprinter 3500 problems:

Engine problems in a 2005 Sprinter 2500 118"WB | Sprinter-Source ...

https://sprinter-source.com/forums/index.php?threads/11368/

May 28, 2010 ... The van has been pretty good to me for the last 5 years. The only issues have been the turbo resonator at 60k, a blown turbo hose at 115k, 2 a/c ...

2005 dodge sprinter problem the wire from the ignition to the starter ...

https://www.justanswer.com/dodge/72lo4-dodge-3500-2005-dodge-sprinter-problem-wire-ignition.html

Aug 26, 2012 ... Dodge 3500: 2005 dodge sprinter problem the wire from the ignition… ... Attachments are only available to registered users. ... Hello, welcome and ...

2005 Dodge Sprinter 3500 crank no start | Sprinter-Source.com

https://sprinter-source.com/forums/index.php?threads/54102/

I have read through most all no start issues on this forum and they are by far more detailed then any other site I have checked out. Thank you again for your ...