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2004 Mercedes-Benz C240

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By Research the Car 5 min read

The 2004 Mercedes-Benz C240 is a compact executive sedan that was part of the W203 generation. It offered a blend of luxury, comfort, and a sporty driving experience. The C240 was primarily equipped with a 2.6-liter V6 engine producing 168 horsepower and 177 lb-ft of torque. Other engine options for the W203 C-Class included a range of inline-4, V6, and V8 engines, along with diesel options in some markets. The available transmissions were typically a 5-speed automatic or a 6-speed manual, depending on the engine and market. Owners often appreciate the car’s elegant styling, comfortable ride, and solid build quality. Common complaints include issues with electrical components, rust, and the cost of maintenance and repairs.

Engine

2.6L V6 (M112)

  • Oil Leaks
    • Description/Symptoms: Oil leaks are common, often originating from the valve cover gaskets, oil filter housing gasket, or front crankshaft seal. Symptoms include visible oil drips under the car, the smell of burning oil, and low oil levels.
    • Solution: Replace the leaking gasket or seal. For valve cover gaskets, replace both sides simultaneously.
    • Estimated Cost to Fix: $200 - $500+
    • Recalls: None Found
  • Mass Air Flow (MAF) Sensor Failure
    • Description/Symptoms: The MAF sensor can fail, leading to poor engine performance, rough idling, stalling, and a check engine light.
    • Solution: Replace the faulty MAF sensor.
    • Estimated Cost to Fix: $150 - $300
    • Recalls: None Found
  • Camshaft Position Sensor Failure
    • Description/Symptoms: Failed camshaft position sensor, leading to poor engine performance, rough idling, stalling, and a check engine light.
    • Solution: Replace the faulty camshaft position sensor.
    • Estimated Cost to Fix: $100 - $200
    • Recalls: None Found

Transmission

5-Speed Automatic (722.6)

  • Transmission Fluid Leaks
    • Description/Symptoms: Leaks can occur from the transmission pan gasket, conductor plate, or the electrical connector bushing (pilot bushing). Symptoms include visible fluid leaks, difficulty shifting, and transmission slipping.
    • Solution: Replace the leaking gasket or bushing. A transmission service, including fluid and filter change, is recommended.
    • Estimated Cost to Fix: $150 - $400+
    • Recalls: None Found
  • Torque Converter Issues
    • Description/Symptoms: The torque converter can fail, causing shuddering during acceleration, especially at lower speeds. This can also lead to poor fuel economy and transmission slippage.
    • Solution: Replace the torque converter.
    • Estimated Cost to Fix: $800 - $1500+
    • Recalls: None Found
  • Valve Body Issues
    • Description/Symptoms: The valve body contains solenoids and valves that control the flow of transmission fluid. These can wear or become clogged, leading to hard shifting, erratic shifting, or failure to shift.
    • Solution: Replace or rebuild the valve body.
    • Estimated Cost to Fix: $500 - $1200+
    • Recalls: None Found

Suspension

  • Worn Control Arm Bushings
    • Description/Symptoms: Control arm bushings wear out over time, leading to clunking noises from the front suspension, especially when going over bumps. Can also cause vague steering and poor handling.
    • Solution: Replace the worn control arm bushings or the entire control arm assembly.
    • Estimated Cost to Fix: $200 - $600+ per arm
    • Recalls: None Found
  • Failed Ball Joints
    • Description/Symptoms: Ball joint failure results in popping or creaking noises from the suspension, loose steering, and uneven tire wear.
    • Solution: Replace the ball joints. It’s often recommended to replace the entire control arm assembly as ball joints may be integral.
    • Estimated Cost to Fix: $200 - $500+ per side
    • Recalls: None Found
  • Broken Coil Springs
    • Description/Symptoms: Coil springs can break, especially in areas with harsh winters and road salt. This leads to a noticeable drop in ride height, a clunking noise, and poor handling.
    • Solution: Replace the broken coil spring. It is recommended to replace both springs on the same axle.
    • Estimated Cost to Fix: $300 - $700+ per pair
    • Recalls: None Found

Electrical

  • Instrument Cluster Failure
    • Description/Symptoms: The instrument cluster can experience various issues, including dimming displays, flickering lights, or complete failure. Individual gauges may also stop working.
    • Solution: Repair or replace the instrument cluster. Some specialized repair shops can rebuild the cluster.
    • Estimated Cost to Fix: $300 - $1000+
    • Recalls: None Found
  • Window Regulator Failure
    • Description/Symptoms: The power windows can fail due to a broken window regulator. The window may become stuck in the up or down position.
    • Solution: Replace the faulty window regulator.
    • Estimated Cost to Fix: $200 - $400 per window
    • Recalls: None Found
  • Door Lock Actuator Failure
    • Description/Symptoms: The door lock actuators can fail, causing the doors to not lock or unlock properly with the remote or interior switch.
    • Solution: Replace the faulty door lock actuator.
    • Estimated Cost to Fix: $150 - $300 per door
    • Recalls: None Found

Exterior

  • Rust Issues
    • Description/Symptoms: The W203 C-Class is prone to rust, especially around the wheel wells, door edges, trunk lid, and underbody.
    • Solution: Repair and repaint the affected areas. Rust prevention treatments can help slow down the process.
    • Estimated Cost to Fix: Varies greatly depending on the severity of the rust.
    • Recalls: None Found
  • Headlight Lens Clouding/Yellowing
    • Description/Symptoms: The plastic headlight lenses tend to become cloudy or yellowed over time, reducing headlight output.
    • Solution: Polish the headlight lenses or replace the headlight assemblies.
    • Estimated Cost to Fix: $50 - $200 for polishing; $200 - $500+ for replacement
    • Recalls: None Found

Interior

  • Center Console Cup Holder Failure
    • Description/Symptoms: The retractable cup holder mechanism in the center console is known to break easily.
    • Solution: Replace the cup holder assembly.
    • Estimated Cost to Fix: $50 - $150
    • Recalls: None Found
  • Sunroof Issues
    • Description/Symptoms: Sunroof malfunctions, including getting stuck, making excessive noise, or leaking water, are relatively common.
    • Solution: Repair or replace the sunroof motor, tracks, or seals.
    • Estimated Cost to Fix: $200 - $800+
    • Recalls: None Found

Summary

The 2004 Mercedes-Benz C240, while offering a luxurious experience, presents owners with several potential issues. Engine oil leaks and transmission problems are common and can be costly to repair. Suspension components like control arm bushings and ball joints are prone to wear, affecting handling. Electrical issues, particularly with the instrument cluster and window regulators, also surface frequently. Rust, especially in certain regions, is a major concern. The severity of these issues ranges from minor inconveniences to major repairs. Potential buyers should carefully inspect the vehicle for these common problems and factor in the cost of potential repairs when considering a purchase.

Mercedes-Benz, C240
Mercedes-Benz C240 2004
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