NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
88 reports62,000 miles · Apr 7, 2009
SteeringInjury
I HAVE A 2002 MERCEDES BENZ (MB) ML320. THE POWER STEERING FLUID WAS DEPLETING ALL THE TIME FROM A LEAKAGE BETWEEN THE POWER STEERING PUMP AND THE HOSE. I TOOK THE VEHICLE TO AN MB DEALERSHIP IN GEORGETOWN, TX (GARLYN SHELTON MERCEDES BENZ DEALERSHIP). THE REPAIR WAS UNDER RECALL, BUT THE DEALERSHIP STILL CHARGED ME $214.16. I …
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I HAVE A 2002 MERCEDES BENZ (MB) ML320. THE POWER STEERING FLUID WAS DEPLETING ALL THE TIME FROM A LEAKAGE BETWEEN THE POWER STEERING PUMP AND THE HOSE. I TOOK THE VEHICLE TO AN MB DEALERSHIP IN GEORGETOWN, TX (GARLYN SHELTON MERCEDES BENZ DEALERSHIP). THE REPAIR WAS UNDER RECALL, BUT THE DEALERSHIP STILL CHARGED ME $214.16. I TOLD THEM THE REPAIR WAS FOR A RECALL, BUT THEY WOULD NOT LET ME TAKE MY CAR WITHOUT PAYMENT, SO I PAID THEM TO HAVE MY CAR BACK. HOWEVER, I'D LIKE NHTSA TO COMPEL THEM OR MERCEDES BENZ TO REFUND ME BACK MY $214.16. I WROTE TO MB HEADQUARTERS IN NEW JERSEY AND THEY SILL REFUSED TO REFUND ME BACK MY MONEY. I HAVE A RECEIPT OF THE REPAIR THAT WAS DONE ON THE CAR AND THE COST THEY BILLED ME. I CAN SEND YOU THE LETTER I WROTE TO MB HEADQUARTERS AND THE REPAIR RECEIPT IF YOU CONTACT ME. I'LL BE GRATEFUL IF YOU CAN HELP ME FROM THIS RIPOFF. *TR
NHTSA ODI #10264322
Mileage unknown · Feb 27, 2009
Steering
TL*THE CONTACT OWNS A 2002 MERCEDES BENZ ML320. WHILE MAKING A TURN AT APPROXIMATELY 35 MPH, THE CONTACT HEARD A LOUD NOISE COMING FROM THE STEERING COLUMN. THE DRIVER HAD TO EXERT GREATER EFFORT TO MAKE A LEFT TURN. THERE WERE NO WARNING INDICATORS ILLUMINATED ON THE INSTRUMENT PANEL. ON SEVERAL OCCASIONS, THE VEHICLE WAS …
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TL*THE CONTACT OWNS A 2002 MERCEDES BENZ ML320. WHILE MAKING A TURN AT APPROXIMATELY 35 MPH, THE CONTACT HEARD A LOUD NOISE COMING FROM THE STEERING COLUMN. THE DRIVER HAD TO EXERT GREATER EFFORT TO MAKE A LEFT TURN. THERE WERE NO WARNING INDICATORS ILLUMINATED ON THE INSTRUMENT PANEL. ON SEVERAL OCCASIONS, THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC TO HAVE THE POWER STEERING FLUID RESERVOIR FILLED BECAUSE IT WAS EXTREMELY LOW. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER FOR DIAGNOSTIC TESTING AND THEY REPAIRED THE VEHICLE ACCORDING TO NHTSA CAMPAIGN ID NUMBER 03V-121. THE POWER STEERING COOLER HOSE AND ONE CLAMP WERE REPLACED; HOWEVER, THE FAILURE STILL PERSISTS. RECENTLY, THE FUEL PUMP HOSE AND CLAMPS WERE REPLACED AT THE CONTACT'S EXPENSE. THE TECHNICIAN RECOMMENDED THAT THE FUEL PUMP BE REPLACED. THE VIN AND MILEAGES WERE UNKNOWN.
NHTSA ODI #10260239
70,000 miles · Feb 12, 2009
Steering
TL*THE CONTACT OWNS A 2002 MERCEDES BENZ ML320. THE CONTACT RECEIVED A RECALL NOTICE AND TOOK THE VEHICLE TO THE DEALER FOR REPAIR. THE DEALER STATED THAT THE O-RING BETWEEN THE POWER STEERING PUMP AND RESERVOIR FAILED. AS A RESULT, THE RECALL REPAIRS WOULD BE INEFFECTIVE WITHOUT ALSO REPLACING THE O-RING. THE DEALER FURTHER…
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TL*THE CONTACT OWNS A 2002 MERCEDES BENZ ML320. THE CONTACT RECEIVED A RECALL NOTICE AND TOOK THE VEHICLE TO THE DEALER FOR REPAIR. THE DEALER STATED THAT THE O-RING BETWEEN THE POWER STEERING PUMP AND RESERVOIR FAILED. AS A RESULT, THE RECALL REPAIRS WOULD BE INEFFECTIVE WITHOUT ALSO REPLACING THE O-RING. THE DEALER FURTHER STATED THAT THE O-RING WOULD NOT BE COVERED BY THE RECALL; THEREFORE, THE CONTACT WOULD HAVE TO PAY AN ESTIMATED COST OF $162 FOR THIS REPAIR. THE NHTSA CAMPAIGN ID NUMBER WAS UNKNOWN. THE FAILURE AND CURRENT MILEAGES WERE LESS THAN 70,000. UPDATED 03/23/09. *LJ UPDATED 03/23/09. *JB
NHTSA ODI #10258519
63,000 miles · Jan 7, 2009
Electrical SystemEngine And Engine CoolingService Brakes, Hydraulic
TL*THE CONTACT OWNS A 2002 MERCEDES BENZ ML320. WHILE DRIVING LESS THAN 70 MPH, THE FRONT PASSENGER SIDE BRAKE LOCKED UP AND CAUSED THE VEHICLE TO SWERVE INTO A MEDIAN. THE ABS WARNING INDICATOR ILLUMINATED ON THE INSTRUMENT PANEL AT THE SAME TIME THE BRAKES LOCKED. THE CONTACT NEVER DEPRESSED THE BRAKE PEDAL NOR THE ACCELERA…
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TL*THE CONTACT OWNS A 2002 MERCEDES BENZ ML320. WHILE DRIVING LESS THAN 70 MPH, THE FRONT PASSENGER SIDE BRAKE LOCKED UP AND CAUSED THE VEHICLE TO SWERVE INTO A MEDIAN. THE ABS WARNING INDICATOR ILLUMINATED ON THE INSTRUMENT PANEL AT THE SAME TIME THE BRAKES LOCKED. THE CONTACT NEVER DEPRESSED THE BRAKE PEDAL NOR THE ACCELERATOR PEDAL FOR THE BRAKES TO LOCK. THE VEHICLE WAS TAKEN TO THE DEALER AND THEY STATED THAT THE YAW RATE SENSOR FAILED. THE REPAIRS WERE SCHEDULED UNDER WARRANTY. THE FAILURE AND CURRENT MILEAGES WERE 63,000. UPDATED 02/05/09 *BF THE BAS/ESP LIGHT ILLUMINATED. THE CATALYTIC CONVERTER WAS CRACKED AND THE TRANSMISSION ELECTRICAL CONNECTOR WAS LEAKING.. UPDATED 02/06/09.*JB
NHTSA ODI #10254094
105,000 miles · Dec 5, 2008
Exterior Lighting
TL*THE CONTACT OWNS A 2002 MERCEDES BENZ ML320. FOR THE PAST TWO YEARS, THE CONTACT HAS TAKEN HER VEHICLE TO THE DEALER TO HAVE THE BRAKE LIGHT SWITCH REPAIRED. WHEN THE BRAKE LIGHT SWITCH FAILED, THE ESP AND ABS INDICATORS ILLUMINATED. THE VEHICLE WOULD STOP AND THE GEAR WOULD HAVE TO BE PLACED INTO PARK TO MANUALLY OVERRIDE…
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TL*THE CONTACT OWNS A 2002 MERCEDES BENZ ML320. FOR THE PAST TWO YEARS, THE CONTACT HAS TAKEN HER VEHICLE TO THE DEALER TO HAVE THE BRAKE LIGHT SWITCH REPAIRED. WHEN THE BRAKE LIGHT SWITCH FAILED, THE ESP AND ABS INDICATORS ILLUMINATED. THE VEHICLE WOULD STOP AND THE GEAR WOULD HAVE TO BE PLACED INTO PARK TO MANUALLY OVERRIDE THE WARNINGS. ONCE THE VEHICLE WAS PLACED INTO PARK, IT WOULD NOT MOVE. THE BRAKES LIGHTS DO NOT ILLUMINATE, WHICH IS A HAZARD TO THE VEHICLES IN THE REAR OF THE CONTACT. THE SWITCH HAS BEEN CHANGED AT LEAST EIGHT TIMES, BUT THE FAILURE STILL OCCURS. THE DEALER STATED THAT THEY SENT AN EMAIL TO THE MERCEDES BENZ MANUFACTURER AT LEAST TWICE, BUT HAVE NOT RECEIVED A RESPONSE. THE DEALER INFORMED THE CONTACT THAT THE REGIONAL MANAGER WOULD INSPECT THE VEHICLE, BUT THIS HAS NOT YET TAKEN PLACE. THE FAILURE MILEAGE WAS 105,000.
NHTSA ODI #10250821
95,000 miles · Dec 2, 2008
Electrical System
VEHICLE'S DRIVE AUTHORIZATION SYSTEM FAILS TO RECOGNIZE KEY RESULTING IN A 'START ERROR' DISPLAYING ON DASH AND VEHICLE WILL NOT START. THIS ITEM CAN ONLY BE REPLACED BY THE DEALER AND IS A KNOWN DEFECT BY MERCEDES BENZ. THE DASH CONTROL UNIT IS PART # A163 545 28 32 AND IS REPLACED BY A MODIFIED VERSION A163 545 07 06. MERCEDES…
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VEHICLE'S DRIVE AUTHORIZATION SYSTEM FAILS TO RECOGNIZE KEY RESULTING IN A 'START ERROR' DISPLAYING ON DASH AND VEHICLE WILL NOT START. THIS ITEM CAN ONLY BE REPLACED BY THE DEALER AND IS A KNOWN DEFECT BY MERCEDES BENZ. THE DASH CONTROL UNIT IS PART # A163 545 28 32 AND IS REPLACED BY A MODIFIED VERSION A163 545 07 06. MERCEDES REQUIRES OWNERS TO BEAR FULL FINANCIAL RESPONSIBILITY FOR THIS REPAIR, EVEN THOUGH IT IS A KNOWN DEFECT WHICH CAN RESULT IN STALLS AND NO START SITUATION, POTENTIALLY PUTTING THE DRIVER AND PASSENGERS IN DANGER. THE COST OF THIS REPAIR IS APPROX. $800 TO $1000. A TECHNICAL SERVICE BULLETIN WAS ISSUED BY MERCEDES BENZ AND THAT BULLETIN IS T-B-80.57/32 AND WAS ISSUED ON FEBRUARY 7, 2005. IT COVERS ALL M CLASS MODELS FROM 2000 TO 2005 MODEL YEAR. *TR
NHTSA ODI #10250462
105,003 miles · Oct 31, 2008
Electronic Stability Control (esc)Vehicle Speed Control
WAS DRIVING VEHICLE ON HIGHWAY AT 75 MPH SET SPEED IN CRUISE CONTROL AND STEPPED ON BRAKE AS I APPROACHED TRAFFIC CONGESTION. VEHICLE WOULD NOT STOP AND CONTINUED TO MAINTAIN SET SPEED REGARDLESS HOW HARD I PRESSED ON THE BRAKE. EVENTUALLY, I DECIDED TO TRY SHIFTING INTO NEUTRAL AND THE VEHICLE WAS PLACED BACK UNDER CONTROL OF T…
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WAS DRIVING VEHICLE ON HIGHWAY AT 75 MPH SET SPEED IN CRUISE CONTROL AND STEPPED ON BRAKE AS I APPROACHED TRAFFIC CONGESTION. VEHICLE WOULD NOT STOP AND CONTINUED TO MAINTAIN SET SPEED REGARDLESS HOW HARD I PRESSED ON THE BRAKE. EVENTUALLY, I DECIDED TO TRY SHIFTING INTO NEUTRAL AND THE VEHICLE WAS PLACED BACK UNDER CONTROL OF THE FOOTBRAKE. THANKFULLY, THE VEHICLE WAS SLOWED DOWN WITHOUT INCIDENT BUT IT WAS A VERY SCARY MOMENT. NOTICED, AT THIS TIME, THE BAS/ESP MALFUNCTION INDICATOR LAMP WAS DISPLAYED ON THE DASHBOARD. DROVE VEHICLE DIRECTLY TO A MERCEDES DEALERSHIP FOR REPAIRS. DEALER ADVISED STOP LAMP SWITCH SHORTED. REPLACED LAMP SWITCH. ALTHOUGH, THIS WAS THE FIRST INCIDENT WHILE IN CRUISE CONTROL THE VEHICLE DID HAVE SIMILAR PAST PROBLEMS WITH THE BRAKING SYSTEM (IE-BRAKE SWITCH AND SHIFTER CONTROL MODULE WERE REPLACED) THAT PREVENTED SHIFTING OUT OF PARK INTO ANY OTHER POSITION. VEHICLE SHOULD HAVE SAFETY DEVICE TO OVERRIDE "CRUISE CONTROL" OR PREVENT "CRUISE CONTROL" OPERATION WITH ANY MALFUNCTION IN THE BRAKING SYSTEM OR ACTIVATION OF THE BRAKING INDICATOR LAMP. WHAT ASSURANCES ARE THERE TO PREVENT THIS FROM HAPPENING AGAIN? *TR
NHTSA ODI #10247405
113,000 miles · Sep 26, 2008
Steering
ON WEDNESDAY, SEPTEMBER 24, 2008, WHILE DRIVING TO WORK MY STEERING WHEEL BECAME DIFFICULT TO TURN. WHEN I LEFT WORK, I NOTICED THAT MOST OF THE STEERING FLUID HAD LEAKED OUT OF MY VEHICLE. THEN ON THURSDAY, A CO WORKER CONTACTED ME AND TOLD ME THAT SHE SAW A RECALL ON THE NEWS ABOUT THE STEERING ON MERCEDES SUV. I IMMEDIATELY C…
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ON WEDNESDAY, SEPTEMBER 24, 2008, WHILE DRIVING TO WORK MY STEERING WHEEL BECAME DIFFICULT TO TURN. WHEN I LEFT WORK, I NOTICED THAT MOST OF THE STEERING FLUID HAD LEAKED OUT OF MY VEHICLE. THEN ON THURSDAY, A CO WORKER CONTACTED ME AND TOLD ME THAT SHE SAW A RECALL ON THE NEWS ABOUT THE STEERING ON MERCEDES SUV. I IMMEDIATELY CONTACTED THE LOCAL DEALER AND WAS TOLD THAT THEY DID NOT HAVE A RECALL IN THEIR SYSTEM FOR MY AUTO AND IT WOULD COST ME $110 TO HAVE THEM DIAGNOSIS MY VEHICLE. I CONTACTED THE 800# THAT WAS ON THE NEWS AND WAS TOLD THAT SOMEONE WILL GET BACK WITH ME. IN THE MEANTIME, I AM A RECENT SINGLE PARENT WITH A 14 YEAR CHILD THAT I TRANSPORT IN A VEHICLE THAT I HAVING A DIFFICULT TIME TO STEER. *TR
NHTSA ODI #10243493
22,000 miles · Aug 4, 2008
Electrical System
TL*THE CONTACT OWNS A 2002 MERCEDES BENZ ML320. WHILE DRIVING 25 MPH, THE INSTRUMENT PANEL LIGHTS ILLUMINATED WITHOUT WARNING. AS A RESULT, THE BRAKE PEDAL EXTENDED TO THE FLOOR WHEN DEPRESSED. THE DEALER STATED THAT A BLOWN FUSE CAUSED THE FAILURE AND THEY MADE THE REPLACEMENT. THE FAILURE RECURRED APPROXIMATELY ONE WEEK LA…
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TL*THE CONTACT OWNS A 2002 MERCEDES BENZ ML320. WHILE DRIVING 25 MPH, THE INSTRUMENT PANEL LIGHTS ILLUMINATED WITHOUT WARNING. AS A RESULT, THE BRAKE PEDAL EXTENDED TO THE FLOOR WHEN DEPRESSED. THE DEALER STATED THAT A BLOWN FUSE CAUSED THE FAILURE AND THEY MADE THE REPLACEMENT. THE FAILURE RECURRED APPROXIMATELY ONE WEEK LATER. THE DEALER STATED THAT THERE WAS ANOTHER BLOWN FUSE AND MADE THE REPLACEMENT AGAIN. THE CONTACT STATED THAT THE DEALER HAS INSPECTED THE VEHICLE APPROXIMATELY 27 TIMES FOR THE SAME FAILURE, BUT THEY HAVE BEEN UNABLE TO DIAGNOSE THE CAUSE OF THE FAILURE. AS OF AUGUST 4, 2008, THE DEALER HAD NOT REPAIRED THE VEHICLE. THE FAILURE MILEAGE WAS 22,000 AND CURRENT MILEAGE WAS 56,000.
NHTSA ODI #10236930
20,500 miles · Jul 28, 2008
Electrical System
TL*THE CONTACT OWNS A 2002 MERCEDES BENZ ML320. A MONTH AFTER PURCHASING THE VEHICLE, THE CONTACT EXPERIENCED DASHBOARD FAILURE. THE HAZARD LIGHTS BEGAN FLASHING ON AND OFF. SHE TOOK THE VEHICLE TO THE DEALER AND THEY DISCOVERED A DEFECT IN THE ELECTRICAL COMPONENT. THEY REPLACED A FUSE, WHICH CORRECTED THE FAILURE FOR APPRO…
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TL*THE CONTACT OWNS A 2002 MERCEDES BENZ ML320. A MONTH AFTER PURCHASING THE VEHICLE, THE CONTACT EXPERIENCED DASHBOARD FAILURE. THE HAZARD LIGHTS BEGAN FLASHING ON AND OFF. SHE TOOK THE VEHICLE TO THE DEALER AND THEY DISCOVERED A DEFECT IN THE ELECTRICAL COMPONENT. THEY REPLACED A FUSE, WHICH CORRECTED THE FAILURE FOR APPROXIMATELY A MONTH, BUT THE FAILURE EVENTUALLY RECURRED. WHEN ALL OF THE LIGHTS ILLUMINATED AGAIN, THEY REMAINED LIT AND LOCKED THE GEARS. THE VEHICLE WAS UNABLE TO BE DRIVEN AND EVEN STALLED WHILE DRIVING 10 MPH. THE CONTACT HAS TAKEN THE VEHICLE BACK TO THE DEALER AT LEAST ONCE PER MONTH AND THEY REPLACED THE FUSE EACH TIME, OR ATTEMPTED TO REPROGRAM THE SYSTEM; HOWEVER, THE REMEDY WAS NEVER PERMANENT. THE VIN WAS UNKNOWN. THE FAILURE MILEAGE WAS 20,500 AND CURRENT MILEAGE WAS 56,000.
NHTSA ODI #10235966
NHTSA investigations
1PE10050 · 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
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