Sprinter vans are known for their versatility, durability, and performance, which is why so many small business owners, delivery drivers, and fleet managers rely on them. Whether you’re using a Sprinter for cargo, passengers, or a custom camper build, keeping it running smoothly is essential. But like any vehicle, Sprinter vans have their own common problems, especially as mileage builds up.

Knowing about these issues will help you spot early warning signs, avoid breakdowns, and stay ahead of repairs. Here are the most common repair concerns we see with Sprinter vans at our repair shops.

1. DEF System and Emissions-Related Problems

Many Sprinter vans use a diesel engine with a DEF (Diesel Exhaust Fluid) system designed to reduce emissions. While this system is important for environmental compliance, it’s also one of the more frequent sources of frustration for owners.

Problems often arise from clogged DEF injectors, sensor failures, or low fluid levels. If the system detects an issue, it can trigger limp mode or restrict performance. Some owners even see a countdown to a no-start condition if DEF-related problems aren’t resolved quickly. Staying on top of DEF fluid levels and servicing emission components helps avoid unexpected downtime.

2. EGR and DPF Blockages

The Exhaust Gas Recirculation (EGR) valve and Diesel Particulate Filter (DPF) are essential parts of a Sprinter’s emissions system, but both can become clogged with carbon buildup over time. This is especially true for vans used for short trips, where the engine doesn’t get hot enough to burn off the soot.

Symptoms of a clogged EGR or DPF include sluggish acceleration, increased fuel consumption, or a check engine light. Left untreated, these issues can lead to more extensive engine damage or costly replacements. Regular driving at highway speeds and professional cleaning services can help reduce buildup.

3. Glow Plug Failures and Starting Issues

Sprinter diesel engines rely on glow plugs to start properly in cold weather. Over time, these plugs can fail, especially in high-mileage vans. You might notice longer cranking times, misfires at startup, or a warning light on the dash.

Replacing glow plugs isn’t always straightforward—some break during removal, especially if they’ve been in place for years. If your Sprinter is having trouble starting or idling rough when cold, it’s worth having the glow plugs inspected sooner rather than later.

4. Suspension Wear From Heavy Loads

Sprinter vans are built to handle weight, but consistent hauling or driving over rough roads puts a lot of stress on suspension components. Worn-out shocks, bushings, control arms, and ball joints are common repairs, especially in vans used for commercial deliveries.

Signs of suspension issues include uneven tire wear, poor handling, a bouncy ride, or clunking sounds over bumps. If your van feels unstable when fully loaded, don’t wait—suspension problems affect safety and can quickly lead to other costly wear and tear.

5. Transmission Trouble in High-Mileage Vans

While Sprinter transmissions are generally reliable, they’re not immune to wear, especially if regular fluid changes have been skipped. Hard shifting, delayed engagement, or slipping are signs that the transmission may need servicing or repair.

Proper maintenance involves flushing the transmission fluid at recommended intervals and inspecting the fluid for signs of debris or contamination. Ignoring early signs can lead to a full rebuild or replacement, which is one of the more expensive repairs you can face.

Rolf’s Import Auto Service – Sprinter Van Specialists in Fife, Tacoma, and Lakewood, WA

At Rolf’s Import Auto Service, we know what it takes to keep a Sprinter van running. Whether you drive for business or adventure, our team is equipped to handle everything from emissions and electrical issues to suspension and drivetrain repairs. With three convenient locations, we make it easy to get expert service, no matter where your Sprinter takes you. Book an appointment today and let us help you keep your van reliable, efficient, and ready for the road.