2009 Dodge Sprinter 3500

The 2009 Dodge Sprinter 3500 is a popular cargo and passenger van known for its versatility and fuel efficiency (especially with the diesel engine). The primary engine option for the 2009 Sprinter 3500 was the 3.0L V6 Turbo Diesel engine. This engine produced around 154 horsepower and 280 lb-ft of torque. The 2009 Sprinter 3500 did not have many engine options. Owners generally appreciate the Sprinter’s cargo capacity, fuel economy (for a large van), and maneuverability. Common complaints often revolve around repair costs, specific component failures (especially related to emissions systems on the diesel), and some electrical gremlins.

Engine

3.0L V6 Turbo Diesel (OM642)

• EGR Valve Failure
  • Description/Symptoms: The Exhaust Gas Recirculation (EGR) valve can become clogged with soot and carbon deposits, leading to rough idling, poor acceleration, and a check engine light. Codes related to EGR flow or performance are common.
  • Solution: Replacement of the EGR valve. Cleaning may provide a temporary fix, but replacement is often necessary.
  • Estimated Cost to Fix: $400 - $800+
  • Recalls: None Found
• Diesel Particulate Filter (DPF) Issues
  • Description/Symptoms: The DPF, designed to trap particulate matter from the exhaust, can become clogged, especially with frequent short trips. Symptoms include reduced power, increased fuel consumption, and warning lights on the dashboard. Regeneration cycles may fail.
  • Solution: Forced regeneration (performed by a mechanic), DPF cleaning, or DPF replacement.
  • Estimated Cost to Fix: $300 (for cleaning) to $2000+ (for replacement)
  • Recalls: None Found
• Turbocharger Failure
  • Description/Symptoms: Gradual or sudden loss of power, loud whistling or screeching noises from the engine compartment, and a check engine light.
  • Solution: Turbocharger replacement.
  • Estimated Cost to Fix: $1500 - $3000+
  • Recalls: None Found
• Oil Cooler Leaks
  • Description/Symptoms: Oil leaks appearing near the oil filter housing or underneath the engine. Can lead to low oil levels and potential engine damage if not addressed.
  • Solution: Replacement of the oil cooler seals or the entire oil cooler assembly.
  • Estimated Cost to Fix: $800 - $1500+
  • Recalls: None Found

Transmission

5-Speed Automatic (NAG1/WA580)

• Torque Converter Shudder
  • Description/Symptoms: Shaking or shuddering during light acceleration or cruising, especially at lower speeds. Often felt in the seat.
  • Solution: Transmission fluid flush using the correct fluid spec (Shell ATF 134 or equivalent), or torque converter replacement if the flush doesn’t resolve the issue.
  • Estimated Cost to Fix: $200 - $400 (fluid flush) to $1000 - $2000+ (torque converter replacement)
  • Recalls: None Found
• Valve Body Issues
  • Description/Symptoms: Hard shifting, delayed engagement, slipping between gears, or complete loss of gear engagement. Can also cause the transmission to get stuck in one gear (limp mode).
  • Solution: Valve body replacement or rebuild.
  • Estimated Cost to Fix: $800 - $2000+
  • Recalls: None Found
• Transmission Conductor Plate Failure
  • Description/Symptoms: The conductor plate (also called the valve body plate) can develop electrical faults or cracks. This can lead to erratic shifting, getting stuck in gear, or transmission codes related to solenoids or speed sensors.
  • Solution: Replacement of the transmission conductor plate.
  • Estimated Cost to Fix: $500 - $1200+
  • Recalls: None Found

Suspension

• Leaf Spring Sagging or Cracking
  • Description/Symptoms: Rear of the van sitting lower than normal, especially when loaded. Can also cause a rough ride and reduced load-carrying capacity. Visible cracks in the leaf springs.
  • Solution: Replacement of the leaf springs.
  • Estimated Cost to Fix: $500 - $1500+ per axle
  • Recalls: None Found
• Sway Bar Link Failure
  • Description/Symptoms: Clunking or rattling noises from the front or rear suspension, especially when going over bumps or turning.
  • Solution: Replacement of the sway bar links.
  • Estimated Cost to Fix: $100 - $300+ per link
  • Recalls: None Found

Electrical

• Glow Plug Failure
  • Description/Symptoms: Hard starting in cold weather, rough idling, and a check engine light. Diesel engines rely on glow plugs to heat the combustion chambers for starting.
  • Solution: Replacement of the faulty glow plug(s).
  • Estimated Cost to Fix: $150 - $500+
  • Recalls: None Found
• SAM (Signal Acquisition Module) Issues
  • Description/Symptoms: The SAM controls various electrical functions, including lights, wipers, and power windows. Problems with the SAM can lead to erratic behavior or failure of these systems.
  • Solution: Diagnosis and repair or replacement of the SAM unit. Often requires specialized programming.
  • Estimated Cost to Fix: $500 - $1500+
  • Recalls: None Found
• Wiring Harness Problems
  • Description/Symptoms: Intermittent electrical issues, such as lights flickering, sensors malfunctioning, or the engine stalling. Often caused by chafed or damaged wiring harnesses, particularly in areas exposed to heat or vibration.
  • Solution: Repair or replacement of the damaged wiring harness sections. Can be time-consuming to diagnose and repair.
  • Estimated Cost to Fix: Varies widely depending on the extent of the damage; $200 - $1000+
  • Recalls: None Found

Exterior

• Sliding Door Roller Failure
  • Description/Symptoms: Difficulty opening or closing the sliding door, binding or grinding noises when operating the door.
  • Solution: Replacement of the sliding door rollers and/or track.
  • Estimated Cost to Fix: $200 - $600+ per door
  • Recalls: None Found
• Rust (Especially Around Wheel Wells and Seams)
  • Description/Symptoms: Visible rust forming around the wheel wells, door seams, and other areas prone to moisture accumulation.
  • Solution: Rust repair and repainting. Prevention is key.
  • Estimated Cost to Fix: $300 - $1000+ per area, depending on severity
  • Recalls: None Found

Interior

• HVAC Blower Motor Failure
  • Description/Symptoms: The heater or air conditioner blower motor stops working, or only works intermittently.
  • Solution: Replacement of the blower motor.
  • Estimated Cost to Fix: $200 - $500+
  • Recalls: None Found
• Dashboard Cracking
  • Description/Symptoms: Cracks can develop on the dashboard, especially in areas exposed to direct sunlight.
  • Solution: Dashboard replacement is a costly repair; some owners opt for a dashboard cover.
  • Estimated Cost to Fix: $800 - $2000+ for replacement; $50 - $200 for a cover
  • Recalls: None Found

Summary:

The 2009 Dodge Sprinter 3500 is generally a reliable van, but owners should be aware of potential issues, particularly with the diesel engine and transmission. The most common problems involve the EGR valve, DPF, turbocharger, and oil cooler on the engine side, and torque converter shudder and valve body problems on the transmission side. Electrical gremlins and suspension wear are also areas to watch. Repair costs can be significant, especially for diesel-related components. Inspecting for rust and properly maintaining the vehicle can help prevent more serious problems down the road.