Underhood Wiring Problems of Dodge Sprinter

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.

See all problems of the 2005 Dodge Sprinter 🔎.

While driving, on highway saw smoke coming from right side of dash, pulled over, flames observed, used fire extinguisher to put out fire under dash. Entire wiring loom for dash and engine were destroyed. $16000+ damage, manufacturer took 3+ months to provide harness.

See all problems of the 2006 Dodge Sprinter 🔎.

We operate 2 2003 Dodge Sprinter passenger vans in our airport shuttle business. On Thursday, may 19th we had a vehicle just quit after start-up when the driver stepped on the gas. She re-started, drove a block, it quits again. We had 6 passengers onbaord to go to the airport. She could not make the vehicle run more than a few blocks and if she stepped on the gas to accelerate it would quit. We towed it to the dealer and the next day it was determined that a wire bundle that runs from the ecu to the engine, which is tied wrapped to 2 other wire bundles had chaffed right thru the protective nylon cover and worn thru 2 or 3 wires in the bundle and completely thur the internal wire. These wires were those that provided voltage to the fuel injectors and hence the failure of power. The dealer was able to splice the wires and put on a heavy duty plastic wire bundle wrap, similar tothose used elsewhere in the vehicle. The problem is that this bundle is tied wrapped to the lower frame of the engine compartment and is probably that way in every Sprinter. Since our Sprinters have about 190,000 miles in only a year and a half, we've obviously have more time and vibration and chaffing than nearly any in the country so we are seeing high mileage issues that a normal consumer will probably never see. However, this instant failure cold have been a disaster we if had been on the freeway going 70 mph instead of in a residential area. We inspected our other Sprinter and it has the same wiring concept but for some reason this main wire bundle was not tie wrapped to the frame and does not appear to be chaffed. We are having our maintenance person check it on Monday the 23rd. This is a true safety issue that should result in at least a recall for inspection of the wire bundle for chaffing. It was about a 3-4 hour repair.

See all problems of the 2003 Dodge Sprinter 🔎.

Driver noticed smoke coming from underneath the vehicle while parked. Driver took vehicle to the dealer for inspection, and mechanic determined that the problem could not duplicated.

See all problems of the 2004 Dodge Sprinter 🔎.