Sprinter vans earn their keep every day, so when they start acting up, it hits both your schedule and your wallet. The good news is that most of the big Sprinter headaches build up slowly, and there are clear warning signs before things get serious. Knowing what to watch for makes it easier to fix problems on your terms instead of on the side of the road.
1. Hard Starting, Rough Idle, and Glow Plug Problems
Sprinters that struggle to fire up on cool mornings, idle roughly for the first minute, or light the glow plug warning light are waving a flag. Weak glow plugs and failing glow plug control modules are common on higher mileage vans. Left alone, they can cause cold starts to be painful and eventually seize the cylinder head plugs.
You might notice a pattern where the van cranks longer than it used to, shakes a bit when it finally catches, then smooths out as it warms. That is the point where it is still usually a straightforward repair. We often suggest testing and replacing bad plugs and addressing module faults before winter, not after you have already had a no-start in the dark.
2. Injector Seal Leaks and the “Black Death” Mess
Sprinter owners talk about “black death,” and it is not just a nickname. When injector seals start leaking, combustion gases and soot escape around the injector bases and mix with oil and dust. Over time, that forms a thick, tar-like buildup around the injectors that looks ugly and makes repairs more difficult.
Early warning signs include a sharp exhaust smell under the hood, a chuffing sound at idle, or damp, dark staining around an injector. If caught early, seals can be replaced and the area cleaned before the buildup gets out of hand. Ignoring it lets the carbon pack in tighter, which can make injector removal much more challenging and expensive later.
3. DEF, DPF, and Emissions System Faults
Modern Sprinter diesels rely on a selective catalytic reduction system and a diesel particulate filter. When everything is working, you barely think about the DEF tank or regeneration cycles. When something goes wrong, you may see a DEF warning, check engine light, reduced power, or countdown messages threatening to limit starts.
Common culprits include faulty NOx sensors, DEF heater issues, clogged DPFs from too many short trips, or low-quality DEF fluid. A lot of owners first notice that the van feels down on power or goes into a limp mode on the highway. Having the system scanned as soon as you see emissions warnings allows repairs before the van locks into stricter limits.
4. Transmission Shudder, Harsh Shifts, or Slipping
Sprinter transmissions work hard, especially in delivery and work fleets that spend all day in city traffic. Old fluid, heavy loads, and a lot of stop and go driving can lead to delayed engagement, harsh shifts, or a shudder when you accelerate through certain speeds. Sometimes you will notice a flare in RPM between gears, like the transmission is slipping before it catches.
A proper service with the correct fluid and filter can help if done before damage progresses too far. Our technicians pay close attention to how the van shifts on a road test and what the fluid looks and smells like when drained. Waiting until the transmission is slipping badly or setting multiple gear ratio codes usually means you are talking about serious internal repairs instead of maintenance.
5. Steering, Suspension Wear, and Front-End Clunks
Sprinters carry tall bodies and heavy cargo, so their front suspensions take a beating. Worn control arm bushings, ball joints, tie rods, and struts can all show up as clunks over bumps, loose or wandering steering, and uneven front tire wear. Sometimes the first sign is a van that feels tired on the highway and wants constant small corrections to stay in its lane.
From a safety standpoint, loose steering and worn suspension also lengthen stopping distances and make emergency maneuvers less stable. Rotating tires and checking alignment help, but if the front end components are worn, they need to be addressed. We look for play at joints, torn boots, and cupped or feathered tread patterns that tell us the suspension has been moving more than it should.
Owner Habits That Make Sprinter Problems Show Up Sooner
How the van is used day to day can either extend its life or bring these common problems forward. Short trips that never let the engine or exhaust fully heat up are tough on DPFs and oil. Pushing oil change intervals too far, or using the wrong specification oil, is rough on turbochargers, timing components, and emissions systems. Overloading the van or running with low tire pressures adds strain to the suspension and brakes.
Simple changes, like sticking to sensible oil intervals, letting the van finish regeneration cycles instead of shutting it off mid-stream, and keeping an eye on tire pressures, go a long way. We have seen two Sprinters with similar mileage look completely different underneath simply because one got regular maintenance and the other was treated like an appliance.
Get Sprinter Repair and Maintenance in Spokane Valley, WA with EuroPro Automotive
If your Sprinter has been hard to start, setting emissions warnings, or just feels less solid than it used to, a focused inspection can keep small issues from turning into downtime. We can check glow plugs, injectors, emissions components, transmission fluid, and suspension wear, then build a maintenance plan that fits how you use your van.
Schedule Sprinter repair and maintenance in Spokane Valley, WA with
EuroPro Automotive, and we will help keep your workhorse on the road and earning.
