NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
44 reports117,000 miles · Oct 25, 2013
Electrical System
THERE IS AN ACTIVE RECALL FOR THE ALL ACTIVITY MODULE ON 2001 M CLASS VEHICLES. THERE IS AN EXTENSIVE AMOUNT OF DATA THAT OWNERS FROM THE RELEASE OF THE MERCEDES BENZ ML430 HAVE HAD PROBLEMS IDENTICAL TO THOSE IN THE ACTIVE RECALL. WHEN I CALL MERCEDES, THEY SAY MY CAR IS NOT IMPACTED. BASED ON THE NUMBER OF ISSUES AND HISTORY O…
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THERE IS AN ACTIVE RECALL FOR THE ALL ACTIVITY MODULE ON 2001 M CLASS VEHICLES. THERE IS AN EXTENSIVE AMOUNT OF DATA THAT OWNERS FROM THE RELEASE OF THE MERCEDES BENZ ML430 HAVE HAD PROBLEMS IDENTICAL TO THOSE IN THE ACTIVE RECALL. WHEN I CALL MERCEDES, THEY SAY MY CAR IS NOT IMPACTED. BASED ON THE NUMBER OF ISSUES AND HISTORY ON 2001 M CLASS ALL ACTIVITY MODULES, I FEEL THIS RECALL SHOULD EXTEND TO ALL 2001 M CLASS CARS.
NHTSA ODI #10549512
131,200 miles · Oct 14, 2013
Service Brakes
I WAS DRIVING AT ABOUT 35 MPH AND ALL OF A SUDDEN I HEARD SCREECHING SOUND FROM MY TIRES AND THE ORANGE TRIANGLE WARNING LIGHT IN MY DASH LIGHT UP. I PULLED OVER AND SHUT OFF THE ENGINE. I NOTICES TIRE SKID MARKS FROM ON THE PASSENGER SIDE. AFTER A FEW MINUTES I STARTED AND DROVE AND THE CAR DROVE NORMAL. THIS SAME THING HAPPENE…
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I WAS DRIVING AT ABOUT 35 MPH AND ALL OF A SUDDEN I HEARD SCREECHING SOUND FROM MY TIRES AND THE ORANGE TRIANGLE WARNING LIGHT IN MY DASH LIGHT UP. I PULLED OVER AND SHUT OFF THE ENGINE. I NOTICES TIRE SKID MARKS FROM ON THE PASSENGER SIDE. AFTER A FEW MINUTES I STARTED AND DROVE AND THE CAR DROVE NORMAL. THIS SAME THING HAPPENED TO MY WIFE ALSO. BASICALLY IT IS LIKE APPLYING THE BRAKES HARD WHILE DRIVING BUT WITH OUT EVEN TOUCHING THE BRAKE. *TR
NHTSA ODI #10547866
175,000 miles · Jun 24, 2013
Service Brakes
TL* THE CONTACT OWNS A 2001 MERCEDES-BENZ ML430. THE CONTACT STATED THE ABS HYDRAULIC UNIT SYSTEM MALFUNCTIONED. THE CONTACT STATED THAT WHILE DRIVING 30 MPH, THE ABS WARNING LIGHT ILLUMINATED AS THE BRAKING SYSTEM INDEPENDENTLY ACTIVED. THE CONTACT HAD TO PULL OVER TO THE SIDE OF THE ROAD AND SHUT THE VEHICLE OFF. THE CONTACT R…
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TL* THE CONTACT OWNS A 2001 MERCEDES-BENZ ML430. THE CONTACT STATED THE ABS HYDRAULIC UNIT SYSTEM MALFUNCTIONED. THE CONTACT STATED THAT WHILE DRIVING 30 MPH, THE ABS WARNING LIGHT ILLUMINATED AS THE BRAKING SYSTEM INDEPENDENTLY ACTIVED. THE CONTACT HAD TO PULL OVER TO THE SIDE OF THE ROAD AND SHUT THE VEHICLE OFF. THE CONTACT RESTARTED THE VEHICLE AND THE BRAKING SYSTEM WAS WORKING NORMAL. THE CONTACT CALLED THE DEALER REGARDING THE ABS SYSTEM. THE DEALER STATED THE ABS HYDRAULIC UNIT NEEDED TO BE REPLACED. THE FAILURE MILEAGE WAS 175,000. THE VIN WAS NOT AVAILABLE.
NHTSA ODI #10521433
99,000 miles · Apr 26, 2013
Service BrakesCrash
TL* THE CONTACT OWNS A 2001 MERCEDES BENZ ML430. THE CONTACT STATED THAT WHEN DRIVING FROM 50 TO 80 MPH, THE VEHICLE BRAKES WOULD SPORADICALLY ENGAGE INDEPENDENTLY AND WITHOUT WARNING. THERE WERE SEVERAL WARNING LIGHTS ILLUMINATED AFTER THE FAILURE OCCURRED. THE VEHICLE AS TAKEN TO A DEALER WHERE A DIAGNOSTIC WAS PERFORMED; HOW…
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TL* THE CONTACT OWNS A 2001 MERCEDES BENZ ML430. THE CONTACT STATED THAT WHEN DRIVING FROM 50 TO 80 MPH, THE VEHICLE BRAKES WOULD SPORADICALLY ENGAGE INDEPENDENTLY AND WITHOUT WARNING. THERE WERE SEVERAL WARNING LIGHTS ILLUMINATED AFTER THE FAILURE OCCURRED. THE VEHICLE AS TAKEN TO A DEALER WHERE A DIAGNOSTIC WAS PERFORMED; HOWEVER, THE CAUSE OF THE FAILURE WAS UNDETERMINED BASED ON THE FAILURE CODES PROVIDED BY THE DIAGNOSTIC. THE FAILURE LATER RECURRED WHILE THE CONTACT WAS DRIVING 50 MPH. AS A RESULT, ANOTHER VEHICLE CRASHED INTO THE REAR OF THE CONTACT'S VEHICLE. THERE WERE NO INJURIES. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 99,000 AND THE CURRENT MILEAGE WAS 102,000. THE VIN WAS NOT AVAILABLE.
NHTSA ODI #10509722
103,249 miles · Feb 26, 2013
Electronic Stability ControlEngine
TL* THE CONTACT OWNS A 2001 MERCEDES BENZ ML430. THE CONTACT STATED THAT WHILE DRIVING 70 MPH, THE VEHICLE SHOOK VIOLENTLY AND MADE A LOUD SOUND. THE VEHICLE WAS TAKEN TO THE DEALER. THE TECHNICIAN DIAGNOSED THAT THE SWITCH BRAKE LIGHT AND THE AIR MASS SENSOR WERE DEFECTIVE AND NEEDED TO BE REPLACED. THE VEHICLE WAS TAKEN TO A D…
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TL* THE CONTACT OWNS A 2001 MERCEDES BENZ ML430. THE CONTACT STATED THAT WHILE DRIVING 70 MPH, THE VEHICLE SHOOK VIOLENTLY AND MADE A LOUD SOUND. THE VEHICLE WAS TAKEN TO THE DEALER. THE TECHNICIAN DIAGNOSED THAT THE SWITCH BRAKE LIGHT AND THE AIR MASS SENSOR WERE DEFECTIVE AND NEEDED TO BE REPLACED. THE VEHICLE WAS TAKEN TO A DIFFERENT DEALER FOR A SECOND OPINION WHERE THE TECHNICIAN STATED THAT THE YAW RATE ELECTRICAL SENSOR FAILED AND NEEDED TO BE REPLACED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE VEHICLE WAS REPAIRED. THE FAILURE MILEAGE WAS 103,249 AND THE CURRENT MILEAGE WAS 103,976. ..UPDATED 04/24/13 *BF THE CONSUMER STATED SEVERAL COMPONENTS WERE REPLACED ON THE VEHICLE. HOWEVER, NONE OF THEM HAVE RECTIFIED THE PROBLEM. THE CONSUMER REFERENCED NHTSA ACTION # PE07007. UPDATED 06/13/13
NHTSA ODI #10500482
114,176 miles · Aug 17, 2012
Engine And Engine CoolingPower Train
I WAS DRIVING HOME CAME TO A CURVE IN THE ROAD ABOUT 15 MPH THE CAR STARTED TO JERK AS IF THE BRAKES WERE BEING ENGAGED, I PULLED OVER TURNED THE CAR OFF TURNED IT BACK ON THE ESP-BAS LIGHT CAME ON. EVER SINCE THEN THE CAR IS UNPREDICTABLE IT HAPPENS EVERYDAY BUT WHEN IT WANTS TO. *TR
NHTSA ODI #10471302
138,000 miles · Jul 18, 2012
Power TrainSteering
IN APPROXIMATELY AUGUST 2010, I HAD AN ESP LIGHT ON. TOOK IT TO THE DEALERSHIP (3 HOURS AWAY) AND THEY REPLACED THE STEERING COLUMN. I PICKED UP THE CAR AND DROVE APPROX 20 MINS WHEN I NOTICED THE STEERING WHEEL WAS NOT ALIGNED. CALLED THE DEALERSHIP AND HAD TO BRING IT BACK IN BECAUSE THEY FORGOT TO ALIGN THE WHEELS. STARTED OF…
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IN APPROXIMATELY AUGUST 2010, I HAD AN ESP LIGHT ON. TOOK IT TO THE DEALERSHIP (3 HOURS AWAY) AND THEY REPLACED THE STEERING COLUMN. I PICKED UP THE CAR AND DROVE APPROX 20 MINS WHEN I NOTICED THE STEERING WHEEL WAS NOT ALIGNED. CALLED THE DEALERSHIP AND HAD TO BRING IT BACK IN BECAUSE THEY FORGOT TO ALIGN THE WHEELS. STARTED OFF ON MY DRIVE BACK HOME, STOPPED FOR GAS AND ON THE WAY OUT THE DRIVEWAY (10 MPH), I HEARD A GRINDING/SQUEAKING NOISE. GOT MY CAR HOME AND FOUND THAT IT WAS LEAKING POWER STEERING FLUID FROM A CLAMP. I KEPT PS FLUID IN THE CAR. TOOK THE CAR BACK TO THE DEALERSHIP IN APPROX. NOVEMBER AND THEY TOLD ME THAT I NEEDED TO HAVE A NEW PS PUMP AND RACK/PINIONS RESEALED, THE COST OF APPROX $1800.00, OF WHICH I CANNOT AFFORD. I HAVE BEEN DRIVING THE CAR, JUST KEEPING PS FLUID IN IT, BUT IT LEAKS OUT. I HAVE NO POWER STEERING. I HAVE HAD THE RECALL CLAMP REPLACE TWICE, ONCE IN 2003 AND THEN IN 2007. *TR
NHTSA ODI #10466514
120,000 miles · Jun 9, 2012
Service Brakes
WHILE DRIVING VEHICLE A 45 MPH AT 5PM IN TRAFFIC, VEHICLE AUTOMATICALLY STARTED ENGAGING BRAKES IN A JERKING MOTION, REPEATEDLY, SUBSEQUENTLY COMING TO A COMPLETE STOP. SMOKE WAS COMING FROM TIRE AREA. THIS HAS HAPPENED REPEATEDLY AND VEHICLE WAS BEING DRIVEN BY MY 16 YEAR OLD. FORTUNATELY, THIS HAS NOT CAUSED AN ACCIDENT. A…
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WHILE DRIVING VEHICLE A 45 MPH AT 5PM IN TRAFFIC, VEHICLE AUTOMATICALLY STARTED ENGAGING BRAKES IN A JERKING MOTION, REPEATEDLY, SUBSEQUENTLY COMING TO A COMPLETE STOP. SMOKE WAS COMING FROM TIRE AREA. THIS HAS HAPPENED REPEATEDLY AND VEHICLE WAS BEING DRIVEN BY MY 16 YEAR OLD. FORTUNATELY, THIS HAS NOT CAUSED AN ACCIDENT. AFTER MUCH RESEARCH, I HAVE FOUND THIS HAS HAPPENED TO SEVERAL OTHER PEOPLE OVER A PERIOD OF TIME IN MERCEDES BENZ'S. THIS IS A SERIOUS SAFETY CONCERN. *JS
NHTSA ODI #10461089
82,000 miles · Apr 14, 2011
Electrical System
TL* THE CONTACT OWNS A 2001 MERCEDES BENZ ML430. THE CONTACT STATED THAT THE ALL ACTIVITY MODULE II, WHICH OPERATES ALL ELECTRICAL COMPONENTS ON THE VEHICLE, FAILED. THE CONTACT REFERENCED NHTSA CAMPAIGN ID NUMBER: 01V061000 (ELECTRICAL SYSTEM: WIRING) WHICH THE DEALER AND THE MANUFACTURER INFORMED THE CONTACT THAT HIS VIN WAS …
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TL* THE CONTACT OWNS A 2001 MERCEDES BENZ ML430. THE CONTACT STATED THAT THE ALL ACTIVITY MODULE II, WHICH OPERATES ALL ELECTRICAL COMPONENTS ON THE VEHICLE, FAILED. THE CONTACT REFERENCED NHTSA CAMPAIGN ID NUMBER: 01V061000 (ELECTRICAL SYSTEM: WIRING) WHICH THE DEALER AND THE MANUFACTURER INFORMED THE CONTACT THAT HIS VIN WAS NOT INCLUDED. THEY OFFERED NO FURTHER ASSISTANCE. THE CONTACT STATED THAT HE WOULD REPAIR THE VEHICLE HIMSELF. THE FAILURE MILEAGE WAS 82,000.
NHTSA ODI #10395832
136,190 miles · Aug 18, 2010
Service Brakes, Hydraulic
TL* THE CONTACT OWNS A 2001 MERCEDES BENZ ML430. WHILE DRIVING APPROXIMATELY 20-25 MPH, THE ABS AND TRACTION WARNING LIGHTS ILLUMINATED. THE CONTACT WAS DEPRESSING THE ACCELERATOR PEDAL WHEN THE BRAKES INDEPENDENTLY ENGAGED AND THE VEHICLE CAME TO A COMPLETE STOP UNEXPECTEDLY. THE CONTACT ACCELERATED AND THE FAILURE RECURRED WIT…
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TL* THE CONTACT OWNS A 2001 MERCEDES BENZ ML430. WHILE DRIVING APPROXIMATELY 20-25 MPH, THE ABS AND TRACTION WARNING LIGHTS ILLUMINATED. THE CONTACT WAS DEPRESSING THE ACCELERATOR PEDAL WHEN THE BRAKES INDEPENDENTLY ENGAGED AND THE VEHICLE CAME TO A COMPLETE STOP UNEXPECTEDLY. THE CONTACT ACCELERATED AND THE FAILURE RECURRED WITH THE BAS AND ESP WARNING LIGHTS ILLUMINATED. THE VEHICLE THEN DROVE AS NORMAL. THE VEHICLE WAS INSPECTED BY A LOCAL MECHANIC WHO ADVISED THAT THE YAW RATE SENSOR WOULD NEED REPLACING. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 136,190 AND THE CURRENT MILEAGE WAS 136,590.
NHTSA ODI #10350362
NHTSA investigations
3PE10050 · Brake Lamp Switch Failure.
Opened Dec 21, 2010 · Closed May 4, 2011
Status: closed (inferred from source dates) · Exterior Lighting:brake Lights:switch; Service Brakes, Hydraulic; Vehicle Speed Control; Vehicle Speed Control:cruise Control
ODI opened the investigation based on reports that the subject vehicle brake lamp switch (switch) failure caused 1) inoperative brake lamps (stay on or fail to illuminate), and/or 2) shift interlock failure (shifter locked in park), and/or 3) the cruise control to fail to cancel with brake application.Consumers also reported the illumination of a warning lamp on the instrument panel.The switch contains three sets of electrical contacts and a (normally extended) spring loaded plunger that actuates the contacts as it moves.As installed in the vehicle, the plunger contacts the brake pedal arm and is pushed into the switch; as the driver applies the pedal the plunger extends.One set of contacts (BLS) operates the stop lamps, a second set (EWM) controls the shift interlock system, and a third set (BS) is used by an on-board diagnostic (OBD) system to monitor switch operation.The cruise control monitors the BLS signal to determine when the brake is applied, the primary way the system is disabled when set.The relative timing of contact actuation in response to plunger movement allows the OBD system to detect a switch fault.When a fault is detected a malfunction indication lamp (MIL) is illuminated (driver alert), a diagnostic trouble code (DTC) is stored (for the service technician), and cruise control operation is inhibited (as a failsafe).In its response to ODI's January 2011 information request letter, MB explained its assessment of switch failures which was based primarily on evaluation of field return failures.MB identified both 1) electrical contact and 2) mechanical switch failure mechanisms.According to MB's analysis, electrical contact failure is the predominate failure type and the failure consequence depends on which contact fails.For instance MB claims that BLS contact failures are momentary in nature and do not affect brake light operation but are nonetheless detected by the OBD system, resulting in a DTC and subsequent replacement.Electrical contact failures of the BS and EWM contacts result in a DTC also, and EWM contact failures result in the shifter being stuck in the park (which can be overridden by the consumer).Accordingly MB maintains that electrical contact failures of the switch have no safety consequence since the brake lamps remain operational and the cruise control is always disabled.MB determined that mechanical failures of the switch, which are rare in their assessment, can result from internal wear and/or increased switch operating temperatures.High temperatures occur due to overheating of the BLS contacts and can cause the internal plastic components to melt.In one scenario overheated BLS contacts may melt to the extended plunger and are damaged when the brake pedal is released resulting in the brake lights staying on.In another scenario the increased temperatures and/or internal wear can cause the plunger to stick in the fully depressed position.In this case the cruise may not cancel when the brake is applied and the driver may have to use high brake pedal forces or other means (shifting to neutral or using the cruise master switch) to disengage the cruise.Additionally the vacuum assist can be depleted if the driver pumps the brakes resulting in reduced braking effectiveness and even higher pedal forces.In its March 31, 2011 defect notification, MB stated that to remediate the potential need for excessive brake force it would conduct a safety recall (11V-208) to replace the switch with a more robustly designed component.The recall includes 136,751 model year 2000 - 2002 M-Class and model year 2000 - 2004 M-Class AMG vehicles.Owner notification letters will be mailed
Additional source detail variants (4)
Exterior Lighting:brake Lights:switch
ODI opened the investigation based on reports that the subject vehicle brake lamp switch (switch) failure caused 1) inoperative brake lamps (stay on or fail to illuminate), and/or 2) shift interlock failure (shifter locked in park), and/or 3) the cruise control to fail to cancel with brake application.Consumers also reported the illumination of a warning lamp on the instrument panel.The switch contains three sets of electrical contacts and a (normally extended) spring loaded plunger that actuates the contacts as it moves.As installed in the vehicle, the plunger contacts the brake pedal arm and is pushed into the switch; as the driver applies the pedal the plunger extends.One set of contacts (BLS) operates the stop lamps, a second set (EWM) controls the shift interlock system, and a third set (BS) is used by an on-board diagnostic (OBD) system to monitor switch operation.The cruise control monitors the BLS signal to determine when the brake is applied, the primary way the system is disabled when set.The relative timing of contact actuation in response to plunger movement allows the OBD system to detect a switch fault.When a fault is detected a malfunction indication lamp (MIL) is illuminated (driver alert), a diagnostic trouble code (DTC) is stored (for the service technician), and cruise control operation is inhibited (as a failsafe).In its response to ODI's January 2011 information request letter, MB explained its assessment of switch failures which was based primarily on evaluation of field return failures.MB identified both 1) electrical contact and 2) mechanical switch failure mechanisms.According to MB's analysis, electrical contact failure is the predominate failure type and the failure consequence depends on which contact fails.For instance MB claims that BLS contact failures are momentary in nature and do not affect brake light operation but are nonetheless detected by the OBD system, resulting in a DTC and subsequent replacement.Electrical contact failures of the BS and EWM contacts result in a DTC also, and EWM contact failures result in the shifter being stuck in the park (which can be overridden by the consumer).Accordingly MB maintains that electrical contact failures of the switch have no safety consequence since the brake lamps remain operational and the cruise control is always disabled.MB determined that mechanical failures of the switch, which are rare in their assessment, can result from internal wear and/or increased switch operating temperatures.High temperatures occur due to overheating of the BLS contacts and can cause the internal plastic components to melt.In one scenario overheated BLS contacts may melt to the extended plunger and are damaged when the brake pedal is released resulting in the brake lights staying on.In another scenario the increased temperatures and/or internal wear can cause the plunger to stick in the fully depressed position.In this case the cruise may not cancel when the brake is applied and the driver may have to use high brake pedal forces or other means (shifting to neutral or using the cruise master switch) to disengage the cruise.Additionally the vacuum assist can be depleted if the driver pumps the brakes resulting in reduced braking effectiveness and even higher pedal forces.In its March 31, 2011 defect notification, MB stated that to remediate the potential need for excessive brake force it would conduct a safety recall (11V-208) to replace the switch with a more robustly designed component.The recall includes 136,751 model year 2000 - 2002 M-Class and model year 2000 - 2004 M-Class AMG vehicles.Owner notification letters will be mailed
Service Brakes, Hydraulic
ODI opened the investigation based on reports that the subject vehicle brake lamp switch (switch) failure caused 1) inoperative brake lamps (stay on or fail to illuminate), and/or 2) shift interlock failure (shifter locked in park), and/or 3) the cruise control to fail to cancel with brake application.Consumers also reported the illumination of a warning lamp on the instrument panel.The switch contains three sets of electrical contacts and a (normally extended) spring loaded plunger that actuates the contacts as it moves.As installed in the vehicle, the plunger contacts the brake pedal arm and is pushed into the switch; as the driver applies the pedal the plunger extends.One set of contacts (BLS) operates the stop lamps, a second set (EWM) controls the shift interlock system, and a third set (BS) is used by an on-board diagnostic (OBD) system to monitor switch operation.The cruise control monitors the BLS signal to determine when the brake is applied, the primary way the system is disabled when set.The relative timing of contact actuation in response to plunger movement allows the OBD system to detect a switch fault.When a fault is detected a malfunction indication lamp (MIL) is illuminated (driver alert), a diagnostic trouble code (DTC) is stored (for the service technician), and cruise control operation is inhibited (as a failsafe).In its response to ODI's January 2011 information request letter, MB explained its assessment of switch failures which was based primarily on evaluation of field return failures.MB identified both 1) electrical contact and 2) mechanical switch failure mechanisms.According to MB's analysis, electrical contact failure is the predominate failure type and the failure consequence depends on which contact fails.For instance MB claims that BLS contact failures are momentary in nature and do not affect brake light operation but are nonetheless detected by the OBD system, resulting in a DTC and subsequent replacement.Electrical contact failures of the BS and EWM contacts result in a DTC also, and EWM contact failures result in the shifter being stuck in the park (which can be overridden by the consumer).Accordingly MB maintains that electrical contact failures of the switch have no safety consequence since the brake lamps remain operational and the cruise control is always disabled.MB determined that mechanical failures of the switch, which are rare in their assessment, can result from internal wear and/or increased switch operating temperatures.High temperatures occur due to overheating of the BLS contacts and can cause the internal plastic components to melt.In one scenario overheated BLS contacts may melt to the extended plunger and are damaged when the brake pedal is released resulting in the brake lights staying on.In another scenario the increased temperatures and/or internal wear can cause the plunger to stick in the fully depressed position.In this case the cruise may not cancel when the brake is applied and the driver may have to use high brake pedal forces or other means (shifting to neutral or using the cruise master switch) to disengage the cruise.Additionally the vacuum assist can be depleted if the driver pumps the brakes resulting in reduced braking effectiveness and even higher pedal forces.In its March 31, 2011 defect notification, MB stated that to remediate the potential need for excessive brake force it would conduct a safety recall (11V-208) to replace the switch with a more robustly designed component.The recall includes 136,751 model year 2000 - 2002 M-Class and model year 2000 - 2004 M-Class AMG vehicles.Owner notification letters will be mailed
Vehicle Speed Control:cruise Control
ODI opened the investigation based on reports that the subject vehicle brake lamp switch (switch) failure caused 1) inoperative brake lamps (stay on or fail to illuminate), and/or 2) shift interlock failure (shifter locked in park), and/or 3) the cruise control to fail to cancel with brake application.Consumers also reported the illumination of a warning lamp on the instrument panel.The switch contains three sets of electrical contacts and a (normally extended) spring loaded plunger that actuates the contacts as it moves.As installed in the vehicle, the plunger contacts the brake pedal arm and is pushed into the switch; as the driver applies the pedal the plunger extends.One set of contacts (BLS) operates the stop lamps, a second set (EWM) controls the shift interlock system, and a third set (BS) is used by an on-board diagnostic (OBD) system to monitor switch operation.The cruise control monitors the BLS signal to determine when the brake is applied, the primary way the system is disabled when set.The relative timing of contact actuation in response to plunger movement allows the OBD system to detect a switch fault.When a fault is detected a malfunction indication lamp (MIL) is illuminated (driver alert), a diagnostic trouble code (DTC) is stored (for the service technician), and cruise control operation is inhibited (as a failsafe).In its response to ODI's January 2011 information request letter, MB explained its assessment of switch failures which was based primarily on evaluation of field return failures.MB identified both 1) electrical contact and 2) mechanical switch failure mechanisms.According to MB's analysis, electrical contact failure is the predominate failure type and the failure consequence depends on which contact fails.For instance MB claims that BLS contact failures are momentary in nature and do not affect brake light operation but are nonetheless detected by the OBD system, resulting in a DTC and subsequent replacement.Electrical contact failures of the BS and EWM contacts result in a DTC also, and EWM contact failures result in the shifter being stuck in the park (which can be overridden by the consumer).Accordingly MB maintains that electrical contact failures of the switch have no safety consequence since the brake lamps remain operational and the cruise control is always disabled.MB determined that mechanical failures of the switch, which are rare in their assessment, can result from internal wear and/or increased switch operating temperatures.High temperatures occur due to overheating of the BLS contacts and can cause the internal plastic components to melt.In one scenario overheated BLS contacts may melt to the extended plunger and are damaged when the brake pedal is released resulting in the brake lights staying on.In another scenario the increased temperatures and/or internal wear can cause the plunger to stick in the fully depressed position.In this case the cruise may not cancel when the brake is applied and the driver may have to use high brake pedal forces or other means (shifting to neutral or using the cruise master switch) to disengage the cruise.Additionally the vacuum assist can be depleted if the driver pumps the brakes resulting in reduced braking effectiveness and even higher pedal forces.In its March 31, 2011 defect notification, MB stated that to remediate the potential need for excessive brake force it would conduct a safety recall (11V-208) to replace the switch with a more robustly designed component.The recall includes 136,751 model year 2000 - 2002 M-Class and model year 2000 - 2004 M-Class AMG vehicles.Owner notification letters will be mailed
Vehicle Speed Control
ODI opened the investigation based on reports that the subject vehicle brake lamp switch (switch) failure caused 1) inoperative brake lamps (stay on or fail to illuminate), and/or 2) shift interlock failure (shifter locked in park), and/or 3) the cruise control to fail to cancel with brake application.Consumers also reported the illumination of a warning lamp on the instrument panel.The switch contains three sets of electrical contacts and a (normally extended) spring loaded plunger that actuates the contacts as it moves.As installed in the vehicle, the plunger contacts the brake pedal arm and is pushed into the switch; as the driver applies the pedal the plunger extends.One set of contacts (BLS) operates the stop lamps, a second set (EWM) controls the shift interlock system, and a third set (BS) is used by an on-board diagnostic (OBD) system to monitor switch operation.The cruise control monitors the BLS signal to determine when the brake is applied, the primary way the system is disabled when set.The relative timing of contact actuation in response to plunger movement allows the OBD system to detect a switch fault.When a fault is detected a malfunction indication lamp (MIL) is illuminated (driver alert), a diagnostic trouble code (DTC) is stored (for the service technician), and cruise control operation is inhibited (as a failsafe).In its response to ODI's January 2011 information request letter, MB explained its assessment of switch failures which was based primarily on evaluation of field return failures.MB identified both 1) electrical contact and 2) mechanical switch failure mechanisms.According to MB's analysis, electrical contact failure is the predominate failure type and the failure consequence depends on which contact fails.For instance MB claims that BLS contact failures are momentary in nature and do not affect brake light operation but are nonetheless detected by the OBD system, resulting in a DTC and subsequent replacement.Electrical contact failures of the BS and EWM contacts result in a DTC also, and EWM contact failures result in the shifter being stuck in the park (which can be overridden by the consumer).Accordingly MB maintains that electrical contact failures of the switch have no safety consequence since the brake lamps remain operational and the cruise control is always disabled.MB determined that mechanical failures of the switch, which are rare in their assessment, can result from internal wear and/or increased switch operating temperatures.High temperatures occur due to overheating of the BLS contacts and can cause the internal plastic components to melt.In one scenario overheated BLS contacts may melt to the extended plunger and are damaged when the brake pedal is released resulting in the brake lights staying on.In another scenario the increased temperatures and/or internal wear can cause the plunger to stick in the fully depressed position.In this case the cruise may not cancel when the brake is applied and the driver may have to use high brake pedal forces or other means (shifting to neutral or using the cruise master switch) to disengage the cruise.Additionally the vacuum assist can be depleted if the driver pumps the brakes resulting in reduced braking effectiveness and even higher pedal forces.In its March 31, 2011 defect notification, MB stated that to remediate the potential need for excessive brake force it would conduct a safety recall (11V-208) to replace the switch with a more robustly designed component.The recall includes 136,751 model year 2000 - 2002 M-Class and model year 2000 - 2004 M-Class AMG vehicles.Owner notification letters will be mailed
EA08009 · Brake Line Chafe
Opened Apr 28, 2008 · Closed Dec 16, 2009
Status: closed (inferred from source dates) · Fuel System, Gasoline:delivery:hoses, Lines/piping, And Fittings; Service Brakes, Hydraulic:foundation Components:hoses, Lines/piping, And Fittings
ANALYSIS OF COMPLAINTS TO ODI AND MERCEDES AND WARRANTY CLAIM DATA SUBMITTED BY MERCEDES INDICATES THAT THE ALLEGED DEFECT HAS OCCURRED AT A LOW RATE (36.5 COMPLAINTS PER 100,000 VEHICLES AND 0.29 PERCENT WARRANTY CLAIM RATE), WITH NO DISCERNABLE DEFECT TREND INDICATING THAT THE RATE OF CHAFING RELATED BRAKE LINE FAILURES IS INCREASING.THERE HAVE BEEN NO NEW COMPLAINTS SINCE JANUARY 2009.WHEN THE ANALYSIS IS LIMITED TO INCIDENTS OF BRAKE LINE LEAKAGE THAT RESULTED IN ALLEGATIONS OF REDUCED BRAKE EFFECTIVENESS, THE RATE DROPS EVEN FURTHER (22.3 COMPLAINTS PER 100,000 VEHICLES AND 0.04 PERCENT WARRANTY CLAIM RATE). MERCEDES PROVIDED DATA SHOWING THAT IN THE RARE INSTANCES WHEN CHAFING DID PROGRESS TO BRAKE LINE LEAKAGE THE DRIVER WOULD BE IMMEDIATELY ALERTED TO A PROBLEM BY ILLUMINATION OF THE BRIGHT YELLOW ESP/BAS WARNING LAMP AND CHANGES IN BRAKE PEDAL FEEL.CONTINUED OPERATION WITH A LEAKING BRAKE LINE WOULD RESULT IN ILLUMINATION OF THE BRIGHT RED BRAKE WARNING LAMP AND AN AUDIBLE CHIME DUE TO LOW MASTER CYLINDER RESERVOIR LEVEL. CONTINUED OPERATION WITH THE BRAKE WARNING LAMP ILLUMINATED WOULD ULTIMATELY DRAIN THE RESERVOIR FOR THE AFFECTED CIRCUIT, RESULTING IN LOSS OF THE CIRCUIT AND AN APPROXIMATELY 80% INCREASE IN STOPPING DISTANCES. SURVEYS CONDUCTED BY ODI AND VRTC INDICATE THAT ROUTING ANOMALIES MAY BE MORE COMMON THAN THE COMPLAINT AND WARRANTY DATA SUGGEST FOR THE SUBJECT LINE BUNDLE, WITH LINE CONTACT OR OTHER ROUTING ANOMALY NOTED IN 13 OF 51 VEHICLES SURVEYED BY ODI AND VRTC (25.5%).WHILE EVIDENCE OF CONTACT BETWEEN THE FUEL LINE AND SUBJECT BRAKE IN A PARTICULAR VEHICLE IS NOT NECESSARILY PREDICTIVE OF EVENTUAL LINE FAILURE/LEAKAGE, SIGNIFICANT CHAFING WEAR WAS NOTED IN TWO SURVEY VEHICLES (3.9%).TO ADDRESS CONCERNS WITH LINE ROUTING AND ENSURE THAT LINES WITH EVIDENT CHAFING DO NOT PROGRESS TO A LEAK CONDITION, MERCEDES WILL CONDUCT AN OWNER NOTIFICATION PROGRAM INSTRUCTING OWNERS TO BRING THE VEHICLES TO A DEALER FOR A FREE INSPECTION AND REPAIR.LINES THAT DO NOT HAVE A SPACER (RUBBER GROMMET OR OMEGA-CLIP) BETWEEN THE SUBJECT FUEL AND BRAKE LINES WILL HAVE AN OMEGA-CLIP SPACER INSTALLED TO ENSURE ADEQUATE CLEARANCE BETWEEN THE LINES.BRAKE LINES WITH CHAFE MARKS WILL BE REPLACED. ACCORDINGLY, THIS INVESTIGATION HAS BEEN CLOSED. THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST. THE AGENCY WILL CONTINUE TO MONITOR COMPLAINTS AND OTHER INFORMATION RELATING TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES AND TAKE FURTHER ACTION IN THE FUTURE IF WARRANTED. FOR ADDITIONAL INFORMATION REGARDING THIS ENGINEERING ANALYSIS REFER TO THE EA08-009 CLOSING REPORT.
Additional source detail variants (2)
Fuel System, Gasoline:delivery:hoses, Lines/piping, And Fittings
ANALYSIS OF COMPLAINTS TO ODI AND MERCEDES AND WARRANTY CLAIM DATA SUBMITTED BY MERCEDES INDICATES THAT THE ALLEGED DEFECT HAS OCCURRED AT A LOW RATE (36.5 COMPLAINTS PER 100,000 VEHICLES AND 0.29 PERCENT WARRANTY CLAIM RATE), WITH NO DISCERNABLE DEFECT TREND INDICATING THAT THE RATE OF CHAFING RELATED BRAKE LINE FAILURES IS INCREASING.THERE HAVE BEEN NO NEW COMPLAINTS SINCE JANUARY 2009.WHEN THE ANALYSIS IS LIMITED TO INCIDENTS OF BRAKE LINE LEAKAGE THAT RESULTED IN ALLEGATIONS OF REDUCED BRAKE EFFECTIVENESS, THE RATE DROPS EVEN FURTHER (22.3 COMPLAINTS PER 100,000 VEHICLES AND 0.04 PERCENT WARRANTY CLAIM RATE). MERCEDES PROVIDED DATA SHOWING THAT IN THE RARE INSTANCES WHEN CHAFING DID PROGRESS TO BRAKE LINE LEAKAGE THE DRIVER WOULD BE IMMEDIATELY ALERTED TO A PROBLEM BY ILLUMINATION OF THE BRIGHT YELLOW ESP/BAS WARNING LAMP AND CHANGES IN BRAKE PEDAL FEEL.CONTINUED OPERATION WITH A LEAKING BRAKE LINE WOULD RESULT IN ILLUMINATION OF THE BRIGHT RED BRAKE WARNING LAMP AND AN AUDIBLE CHIME DUE TO LOW MASTER CYLINDER RESERVOIR LEVEL. CONTINUED OPERATION WITH THE BRAKE WARNING LAMP ILLUMINATED WOULD ULTIMATELY DRAIN THE RESERVOIR FOR THE AFFECTED CIRCUIT, RESULTING IN LOSS OF THE CIRCUIT AND AN APPROXIMATELY 80% INCREASE IN STOPPING DISTANCES. SURVEYS CONDUCTED BY ODI AND VRTC INDICATE THAT ROUTING ANOMALIES MAY BE MORE COMMON THAN THE COMPLAINT AND WARRANTY DATA SUGGEST FOR THE SUBJECT LINE BUNDLE, WITH LINE CONTACT OR OTHER ROUTING ANOMALY NOTED IN 13 OF 51 VEHICLES SURVEYED BY ODI AND VRTC (25.5%).WHILE EVIDENCE OF CONTACT BETWEEN THE FUEL LINE AND SUBJECT BRAKE IN A PARTICULAR VEHICLE IS NOT NECESSARILY PREDICTIVE OF EVENTUAL LINE FAILURE/LEAKAGE, SIGNIFICANT CHAFING WEAR WAS NOTED IN TWO SURVEY VEHICLES (3.9%).TO ADDRESS CONCERNS WITH LINE ROUTING AND ENSURE THAT LINES WITH EVIDENT CHAFING DO NOT PROGRESS TO A LEAK CONDITION, MERCEDES WILL CONDUCT AN OWNER NOTIFICATION PROGRAM INSTRUCTING OWNERS TO BRING THE VEHICLES TO A DEALER FOR A FREE INSPECTION AND REPAIR.LINES THAT DO NOT HAVE A SPACER (RUBBER GROMMET OR OMEGA-CLIP) BETWEEN THE SUBJECT FUEL AND BRAKE LINES WILL HAVE AN OMEGA-CLIP SPACER INSTALLED TO ENSURE ADEQUATE CLEARANCE BETWEEN THE LINES.BRAKE LINES WITH CHAFE MARKS WILL BE REPLACED. ACCORDINGLY, THIS INVESTIGATION HAS BEEN CLOSED. THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST. THE AGENCY WILL CONTINUE TO MONITOR COMPLAINTS AND OTHER INFORMATION RELATING TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES AND TAKE FURTHER ACTION IN THE FUTURE IF WARRANTED. FOR ADDITIONAL INFORMATION REGARDING THIS ENGINEERING ANALYSIS REFER TO THE EA08-009 CLOSING REPORT.
Service Brakes, Hydraulic:foundation Components:hoses, Lines/piping, And Fittings
ANALYSIS OF COMPLAINTS TO ODI AND MERCEDES AND WARRANTY CLAIM DATA SUBMITTED BY MERCEDES INDICATES THAT THE ALLEGED DEFECT HAS OCCURRED AT A LOW RATE (36.5 COMPLAINTS PER 100,000 VEHICLES AND 0.29 PERCENT WARRANTY CLAIM RATE), WITH NO DISCERNABLE DEFECT TREND INDICATING THAT THE RATE OF CHAFING RELATED BRAKE LINE FAILURES IS INCREASING.THERE HAVE BEEN NO NEW COMPLAINTS SINCE JANUARY 2009.WHEN THE ANALYSIS IS LIMITED TO INCIDENTS OF BRAKE LINE LEAKAGE THAT RESULTED IN ALLEGATIONS OF REDUCED BRAKE EFFECTIVENESS, THE RATE DROPS EVEN FURTHER (22.3 COMPLAINTS PER 100,000 VEHICLES AND 0.04 PERCENT WARRANTY CLAIM RATE). MERCEDES PROVIDED DATA SHOWING THAT IN THE RARE INSTANCES WHEN CHAFING DID PROGRESS TO BRAKE LINE LEAKAGE THE DRIVER WOULD BE IMMEDIATELY ALERTED TO A PROBLEM BY ILLUMINATION OF THE BRIGHT YELLOW ESP/BAS WARNING LAMP AND CHANGES IN BRAKE PEDAL FEEL.CONTINUED OPERATION WITH A LEAKING BRAKE LINE WOULD RESULT IN ILLUMINATION OF THE BRIGHT RED BRAKE WARNING LAMP AND AN AUDIBLE CHIME DUE TO LOW MASTER CYLINDER RESERVOIR LEVEL. CONTINUED OPERATION WITH THE BRAKE WARNING LAMP ILLUMINATED WOULD ULTIMATELY DRAIN THE RESERVOIR FOR THE AFFECTED CIRCUIT, RESULTING IN LOSS OF THE CIRCUIT AND AN APPROXIMATELY 80% INCREASE IN STOPPING DISTANCES. SURVEYS CONDUCTED BY ODI AND VRTC INDICATE THAT ROUTING ANOMALIES MAY BE MORE COMMON THAN THE COMPLAINT AND WARRANTY DATA SUGGEST FOR THE SUBJECT LINE BUNDLE, WITH LINE CONTACT OR OTHER ROUTING ANOMALY NOTED IN 13 OF 51 VEHICLES SURVEYED BY ODI AND VRTC (25.5%).WHILE EVIDENCE OF CONTACT BETWEEN THE FUEL LINE AND SUBJECT BRAKE IN A PARTICULAR VEHICLE IS NOT NECESSARILY PREDICTIVE OF EVENTUAL LINE FAILURE/LEAKAGE, SIGNIFICANT CHAFING WEAR WAS NOTED IN TWO SURVEY VEHICLES (3.9%).TO ADDRESS CONCERNS WITH LINE ROUTING AND ENSURE THAT LINES WITH EVIDENT CHAFING DO NOT PROGRESS TO A LEAK CONDITION, MERCEDES WILL CONDUCT AN OWNER NOTIFICATION PROGRAM INSTRUCTING OWNERS TO BRING THE VEHICLES TO A DEALER FOR A FREE INSPECTION AND REPAIR.LINES THAT DO NOT HAVE A SPACER (RUBBER GROMMET OR OMEGA-CLIP) BETWEEN THE SUBJECT FUEL AND BRAKE LINES WILL HAVE AN OMEGA-CLIP SPACER INSTALLED TO ENSURE ADEQUATE CLEARANCE BETWEEN THE LINES.BRAKE LINES WITH CHAFE MARKS WILL BE REPLACED. ACCORDINGLY, THIS INVESTIGATION HAS BEEN CLOSED. THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST. THE AGENCY WILL CONTINUE TO MONITOR COMPLAINTS AND OTHER INFORMATION RELATING TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES AND TAKE FURTHER ACTION IN THE FUTURE IF WARRANTED. FOR ADDITIONAL INFORMATION REGARDING THIS ENGINEERING ANALYSIS REFER TO THE EA08-009 CLOSING REPORT.
PE07007 · Electronic Stability Control Malfunction
Opened Feb 1, 2007 · Closed Jul 11, 2007
Status: closed (inferred from source dates) · Electronic Stability Control:automatic (asc)
ODI OPENED PE07-007 AFTER RECEIVING 4 COMPLAINTS WITHIN A 6 WEEK PERIOD ALLEGING INCIDENTS OF UNCOMMANDED BRAKE APPLICATION IN MODEL YEAR (MY) 2000 THROUGH 2001 MERCEDES M CLASS SPORT UTILITY VEHICLES.INFORMATION CONTAINED IN THE REPORTS OR GATHERED IN SUBSEQUENT CONSUMER INTERVIEWS INDICATED THAT THE INCIDENTS WERE CAUSED BY FAULTS IN THE ELECTRONIC STABILITY PROGRAM (ESP) SYSTEM WHICH WERE REPAIRED BY REPLACING THE YAW RATE SENSORS.ALTHOUGH THE SAME YAW RATE SENSOR IS USED IN APPROXIMATELY 800,000 OTHER MERCEDES M-CLASS, C-CLASS AND SLK MODELS, TO DATE THERE HAS BEEN ONLY ONE RELATED COMPLAINT TO ODI IN THOSE VEHICLES. DURING THIS INVESTIGATION MERCEDES BENZ PROVIDED ODI WITH 327 COMPLAINTS RELATED TO THE ESP SYSTEM IN THE MY 2000 THROUGH 2001 M CLASS VEHICLES.SEVEN OF THE COMPLAINTS SUBMITTED BY MERCEDES ALLEGED INCIDENTS OF UNCOMMANDED BRAKE ACTIVATION WHILE DRIVING, WITH TWO OF THESE INVOLVING VEHICLES IDENTIFIED IN THE ODI COMPLAINTS.NONE OF THE INCIDENTS RESULTED IN CRASH OR INJURY.HOWEVER, THE OWNERS DID EXPRESS SAFETY CONCERNS DUE TO THE SUDDEN, UNEXPECTED CHANGE IN VEHICLE SPEED AND DIRECTION. ON MAY 10, 2007 MERCEDES BENZ MET WITH NHTSA TO PROVIDE A TECHNICAL PRESENTATION AND CONDUCT A DRIVING DEMONSTRATION OF THE ESP SYSTEM PERFORMANCE WITH SIMULATED ELECTRICAL FAULTS IN THE YAW RATE SENSOR.MERCEDES SHOWED THAT THE ESP SYSTEM IS PROGRAMMED TO DIAGNOSE ELECTRICAL FAULTS AND THAT BRAKE APPLICATIONS RESULTING FROM YAW RATE SENSOR ELECTRICAL FAULTS ARE VERY SHORT IN DURATION (0.3 SECONDS OR LESS) AND DO NOT AFFECT VEHICLE CONTROL OR STABILITY. NINE OF THE CONSUMER COMPLAINTS TO ODI AND MERCEDES ALLEGED BRAKE ACTIVATIONS LONGER THAN 0.3 SECONDS, WITH SEVERAL ALLEGING THAT THE INCIDENT LASTED UNTIL THE VEHICLE CAME TO A STOP.A COMPLAINT VEHICLE THAT ALLEGED MULTIPLE INCIDENTS WAS EVALUATED BY ODI AT THE VEHICLE RESEARCH AND TEST CENTER (VRTC) IN EAST LIBERTY, OHIO.VRTC WAS UNABLE TO DUPLICATE THE CONDITION.DUE TO THE LOW COMPLAINT RATE AND ONLY ONE NEW COMPLAINT TO ODI OR MERCEDES SINCE JANUARY 2007, THIS INVESTIGATION HAS BEEN CLOSED.ODI WILL CONTINUE TO MONITOR COMPLAINTS IN THE SUBJECT VEHICLES AND OTHER MERCEDES PRODUCTS USING THE SAME YAW RATE SENSOR AND MERCEDES WILL PROVIDE UPDATES ON FIELD EXPERIENCE (COMPLAINTS, FIELD REPORTS AND WARRANTY CLAIMS) THROUGH THE END OF 2007.
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