Tank Assembly problems of the 2004 Mercedes Benz E500

Three problems related to tank assembly have been reported for the 2004 Mercedes Benz E500. The most recently reported issues are listed below.

1 Tank Assembly problem

Failure Date: 05/30/2013

For the past several months after filling the vehicle a strong gas smell/fumes are present in the vehicle. The smell/fumes subside when approximately 1/4 of the fuel in the tank has been used. On Friday may 31st 2013 the vehicle was filled with fuel. Parked the vehicle in the garage Friday night and was knocked over by gas smell/fumes on Saturday morning, June 1st 2013. The vehicle was parked outside overnight. After researching the issue, I found fuel around the sending unit under the drive side back seat. The fuel was removed and the sending unit cleaned. The sending unit was observed see if a leak could be detected on the unit. The leak is at the top part of the sending unit. The part where the small wire plug is attached to the sending unit. It looks like this part is "glued" to the body of the sending unit. Short term fix is to only fill the fuel tank half way. This hazard, if not rectified by the manufacture makes mine and all other vehicles unsafe and un-sellable on the used car market.

2 Tank Assembly problem

Failure Date: 01/12/2011

Strong gas odor from left rear wheel area after filling tank fully. Stops leaking fuel when tank reaches about 3/4 full.

3 Tank Assembly problem

Failure Date: 11/02/2010

The contact owns 2004 Mercedes Benz E500. The contact stated while driving 65 mph the warning light "brake failure and esp failure" were displayed and also indicated that the contact should drive onto the emergency lane. The contact was unable to stop the vehicle by applying the brakes; however, when he was able to stop it by downshifting and engaging the emergency brake. The contact stated this could have caused a major crash. The vehicle was towed to a local mechanic who was performing a diagnostic test when the complaint was filed. The contact did not call the manufacturer. The contact had also viewed numerous complaints via the internet regarding brake failure for his year, make and model vehicle. The contact stated the manufacturer was not issued a recall but was fully aware of the brake system failure. The failure mileage was 67,000. Updated 01/13/bf the consumer also stated there was a smell of gas. It was determined the gas tank was cracked. Also, the front ball joint broke. The consumer has since traded the vehicle. Updated 01/24/11.


Other Gasoline Fuel System related problems of the 2004 Mercedes Benz E500



E500 Service Bulletins
E500 Defect Investigations