2009 Mercedes-Benz Boxer OF

The 2009 Mercedes-Benz Boxer OF is a chassis designed for various commercial applications, including buses and vans. While specific horsepower and torque figures vary based on the final application and engine configuration, these chassis were typically equipped with diesel engines known for their reliability and durability in heavy-duty use. Owners often appreciate the Boxer OF for its robust construction and suitability for demanding applications. However, potential drawbacks include maintenance costs associated with commercial-grade vehicles and potential issues related to specific upfitting or modifications performed by third parties. This chassis was most commonly equipped with an inline 4-cylinder or inline 6-cylinder diesel engine. Transmission options varied based on customer specifications, but usually consisted of a manual transmission or an automatic transmission.

Engine

Inline 4-Cylinder Diesel

• Fuel Injector Failure
  • Description/Symptoms: Rough idling, poor fuel economy, black smoke from the exhaust, and difficulty starting.
  • Solution: Replace the faulty fuel injector(s).
  • Estimated Cost to Fix: $400 - $800+ per injector (depending on labor rates and parts availability)
  • Recalls: None Found
• Turbocharger Failure
  • Description/Symptoms: Loss of power, whistling or whining noise from the engine, black smoke from the exhaust, and increased oil consumption.
  • Solution: Replace or rebuild the turbocharger.
  • Estimated Cost to Fix: $1500 - $3500+ (depending on labor rates and parts availability)
  • Recalls: None Found

Inline 6-Cylinder Diesel

• Cylinder Head Cracking
  • Description/Symptoms: Overheating, coolant loss, white smoke from the exhaust, and coolant mixing with oil.
  • Solution: Replace the cylinder head.
  • Estimated Cost to Fix: $3000 - $6000+ (depending on labor rates and parts availability)
  • Recalls: None Found
• EGR Valve Failure
  • Description/Symptoms: Rough idling, poor fuel economy, black smoke from the exhaust, and engine stalling.
  • Solution: Replace the EGR valve.
  • Estimated Cost to Fix: $500 - $1200+ (depending on labor rates and parts availability)
  • Recalls: None Found

Transmission

Manual Transmission

• Synchro Wear
  • Description/Symptoms: Grinding or difficulty shifting into specific gears, especially 2nd or 3rd gear.
  • Solution: Rebuild or replace the transmission, including replacing worn synchros.
  • Estimated Cost to Fix: $2000 - $4000+ (depending on labor rates and parts availability)
  • Recalls: None Found
• Clutch Failure
  • Description/Symptoms: Slipping clutch, difficulty shifting, unusual noises when engaging the clutch, and complete clutch failure.
  • Solution: Replace the clutch disc, pressure plate, and throw-out bearing. Resurface or replace the flywheel.
  • Estimated Cost to Fix: $800 - $2000+ (depending on labor rates and parts availability)
  • Recalls: None Found

Automatic Transmission

• Torque Converter Failure
  • Description/Symptoms: Shuddering during acceleration, poor fuel economy, and transmission slipping.
  • Solution: Replace the torque converter.
  • Estimated Cost to Fix: $1500 - $3000+ (depending on labor rates and parts availability)
  • Recalls: None Found
• Valve Body Issues
  • Description/Symptoms: Harsh or erratic shifting, delayed engagement, and transmission slipping.
  • Solution: Replace or rebuild the valve body.
  • Estimated Cost to Fix: $1000 - $2500+ (depending on labor rates and parts availability)
  • Recalls: None Found

Suspension

• Air Suspension System Leaks (if equipped)
  • Description/Symptoms: Vehicle leaning to one side, compressor running constantly, and a loss of ride height.
  • Solution: Identify and repair leaks in the air lines, air springs, or compressor. Replace faulty components as needed.
  • Estimated Cost to Fix: $300 - $2000+ (depending on the location and severity of the leak)
  • Recalls: None Found
• Leaf Spring Sagging/Cracking (if equipped)
  • Description/Symptoms: Reduced ride height, poor ride quality, and visible cracking in the leaf springs.
  • Solution: Replace the leaf springs.
  • Estimated Cost to Fix: $500 - $1500+ per spring (depending on labor rates and parts availability)
  • Recalls: None Found

Electrical

• Wiring Harness Issues
  • Description/Symptoms: Intermittent electrical problems, such as lights flickering, gauges not working, and starting issues.
  • Solution: Inspect and repair damaged wiring harnesses. Replace corroded connectors.
  • Estimated Cost to Fix: $200 - $2000+ (depending on the severity and location of the damage)
  • Recalls: None Found
• Alternator Failure
  • Description/Symptoms: Dimming headlights, warning lights on the dashboard, and difficulty starting the engine.
  • Solution: Replace the alternator.
  • Estimated Cost to Fix: $300 - $800+ (depending on labor rates and parts availability)
  • Recalls: None Found

Exterior

• Rust Issues (especially in areas with road salt)
  • Description/Symptoms: Rust forming on body panels, frame, and undercarriage.
  • Solution: Repair or replace rusted panels. Apply rustproofing treatments.
  • Estimated Cost to Fix: $500 - $5000+ (depending on the severity of the rust)
  • Recalls: None Found
• Lighting Issues
  • Description/Symptoms: Headlights, taillights, or turn signals not working properly.
  • Solution: Replace bulbs, repair wiring, or replace the entire light assembly.
  • Estimated Cost to Fix: $50 - $500+ (depending on the complexity)
  • Recalls: None Found

Interior

• HVAC System Issues
  • Description/Symptoms: Weak airflow, no heat or air conditioning, and unusual noises from the HVAC system.
  • Solution: Repair or replace the blower motor, compressor, or other HVAC components.
  • Estimated Cost to Fix: $200 - $1500+ (depending on the specific issue)
  • Recalls: None Found
• Dashboard Cracking/Delamination
  • Description/Symptoms: Cracks forming on the dashboard surface, or the dashboard material separating from the underlying structure.
  • Solution: Replace or repair the dashboard.
  • Estimated Cost to Fix: $500 - $2000+ (depending on the method)
  • Recalls: None Found

Summary

The 2009 Mercedes-Benz Boxer OF can experience a range of issues, from engine and transmission problems to suspension, electrical, exterior, and interior concerns. The severity and cost of repairs can vary significantly depending on the specific issue and the extent of the damage. Engine and transmission repairs tend to be the most expensive, while electrical and interior issues can often be resolved at a lower cost. Rust is a common concern, especially in regions with harsh winters. Potential buyers should carefully inspect the vehicle for these common issues and factor in potential repair costs when making a purchase decision.