My infatuation with the sprinter van is quickly fading. Did a lot of reasearch past few days...Heres the major problems that have been discovered on various sprinter owner boards:

1)ERG valve blowing oil all over (Not just a small leak) - multiple replacements
2) problems with harmonic balancers literally exploding (This is the #1 complaint)- Mercedes admits to faulty metal alloy being used, I guess the design is also at fault - one report of damage done to the crankshaft because of this - engine needs replacement, out of warranty - $12,000 job, youch!
3) Torque converters needing replacement
3) One report of engine failure at 23,000 miles (Covered by warranty)
4) loss of power when tach approaches 3,000 rpm (a few owners submitted same problem)
4) One company owns 10 - a few of the vans spend a lot of time in the shop - all under warranty, BUT the owner said down time is affecting his bottom line.

These are all of the MAJOR problems that i've discovered, some minor ones also, but all vans have their glitches, so I didnt bother with them.

Sorry for the long post, but I figured this might help someone with a decision if they're looking at the sprinter. The e-350 ford diesel just got bumped to the #1 spot again for me...

Joe

PS it seemed to me most of the problems were from the 2003 model year, but some 2005 engine replacements were noted...

I have a 2002 Ford E350 with a Triton 5.4 V8. It has 53,000 mi.
Thurs. it blew a spark plug out of the head. Is a $3,000 to $3,500 fix. I don't have an extended service plan. So far NOBODY wants to help me.
I did some research and it turns out to be a common problem that Ford will not admit. A lawyer in CA is trying to get the Feds to force Ford to issue a recall on 17.5 MILLION vehicles. The V10 has the same problem but not sure what years. I know a diesel has no plugs so you won't have that problem. Check it out before signing on the line.
I have a slide-in mounted in this thing. If they only do a heilacoil fix I'm selling it. I may go completely portable - Steamin Demon, Cimex, encap and add some OP.