2005 Mercedes-Benz Boxer 50

The 2005 Mercedes-Benz Boxer 50, also known as the Sprinter in some markets, is a light commercial van popular for its versatility and cargo capacity. The 2005 model year offered several engine options, including diesel variants, such as the 2.7L inline-5 cylinder diesel engine. There were a variety of transmission options available, most commonly an automatic transmission and a manual transmission. Owners generally appreciate the Sprinter’s cargo space and reliability, but common complaints revolve around repair costs and some specific component failures. This breakdown covers some of the most frequently reported issues.

Engine

2.7L Inline-5 Cylinder Diesel

• Black Death (Injector Seal Leaks)
  • Description/Symptoms: Diesel fuel leaks around the base of the fuel injectors, creating a tar-like buildup. This leads to a strong diesel fuel smell, poor engine performance, and potential damage to surrounding components.
  • Solution: Replacing the injector seals is necessary. In severe cases, the injectors may need to be removed and cleaned or replaced if they are seized.
  • Estimated Cost to Fix: $300 - $1000+ depending on the severity and number of injectors affected.
  • Recalls: None Found
• Turbocharger Failure
  • Description/Symptoms: Loss of power, excessive black smoke from the exhaust, and a whistling noise from the turbocharger.
  • Solution: Replacement of the turbocharger.
  • Estimated Cost to Fix: $1500 - $3000+ depending on the shop and parts used.
  • Recalls: None Found
• Glow Plug Issues
  • Description/Symptoms: Hard starting, especially in cold weather, and a check engine light.
  • Solution: Replacing the faulty glow plugs and possibly the glow plug module.
  • Estimated Cost to Fix: $200 - $500+
  • Recalls: None Found

Transmission

Automatic Transmission

• Slipping or Harsh Shifting
  • Description/Symptoms: Transmission slips between gears, hesitates when shifting, or shifts harshly.
  • Solution: Fluid flush may help with minor issues. Valve body replacement or complete transmission rebuild/replacement may be necessary for more severe cases.
  • Estimated Cost to Fix: $200 (fluid flush) - $4000+ (rebuild/replacement)
  • Recalls: None Found

Suspension

• Leaf Spring Failure
  • Description/Symptoms: Sagging rear end, poor ride quality, and potentially a cracked or broken leaf spring. This is more common on vans that are frequently loaded heavily.
  • Solution: Replacing the leaf springs. It’s generally recommended to replace them in pairs.
  • Estimated Cost to Fix: $500 - $1500+
  • Recalls: None Found

Electrical

• Faulty ABS Control Module
  • Description/Symptoms: ABS light illuminated, potential loss of ABS function, and diagnostic trouble codes related to the ABS module.
  • Solution: Replacement of the ABS control module. May require programming.
  • Estimated Cost to Fix: $500 - $1500+
  • Recalls: None Found
• Wiring Harness Issues
  • Description/Symptoms: Intermittent electrical problems, such as lights not working, sensors malfunctioning, or starting issues. This is often due to chafing or corrosion of the wiring harness.
  • Solution: Diagnosing and repairing the damaged wires or replacing sections of the wiring harness.
  • Estimated Cost to Fix: $200 - $1000+ depending on the severity and location of the damage.
  • Recalls: None Found

Exterior

• Rust (Especially around Wheel Arches and Body Seams)
  • Description/Symptoms: Visible rust on the body panels, particularly around the wheel arches, rocker panels, and body seams.
  • Solution: Rust repair, which may involve sanding, patching, and repainting. In severe cases, panel replacement may be necessary.
  • Estimated Cost to Fix: $300 - $2000+ depending on the severity and extent of the rust.
  • Recalls: None Found

Interior

• Door Lock Actuator Failure
  • Description/Symptoms: Doors not locking or unlocking properly with the key fob or interior switch.
  • Solution: Replacing the faulty door lock actuator.
  • Estimated Cost to Fix: $150 - $400+ per door.
  • Recalls: None Found

Summary

The 2005 Mercedes-Benz Boxer 50 (Sprinter) is generally a reliable van, but owners should be aware of potential issues, especially with the diesel engine and transmission. The “Black Death” injector seal leaks and turbocharger failures on the 2.7L diesel can be costly to repair. Electrical problems and rust are also common concerns. While some repairs are relatively inexpensive, others, such as transmission rebuilds or turbocharger replacements, can be significant expenses. Pre-purchase inspections are recommended to identify potential problems before buying a used 2005 Sprinter.