Check Transmission Wiring Harness Connector – 2019-2023 Mercedes-Benz CLS-Class, E-Class, & GT-Class

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July 22, 2022 NHTSA CAMPAIGN NUMBER: 22V533000

Misrouted Harness May Corrode and Short-Circuit

An electrical short-circuit can increase the risk of a fire.

 

NHTSA Campaign Number: 22V533

Manufacturer Mercedes-Benz USA, LLC

Components ELECTRICAL SYSTEM

Potential Number of Units Affected 27,330

 

Summary

Mercedes-Benz USA, LLC (MBUSA) is recalling certain 2021-2023 AMG GT43, E450 Cabriolet, E450 Wagon, E450 Coupe, 2019-2023 AMG E53, E53 Coupe, E53 Cabriolet, AMG GT53, CLS450, and 2019-2021 AMG CLS53 vehicles. The transmission wiring harness may be misrouted, which can expose the electrical connector to corrosion, and result in an electrical short-circuit.

 

Remedy

Dealers will inspect and repair the electrical connector, as necessary. Dealers will also reroute the harness and install an additional bracket. All repairs will be performed free of charge. Owner notification letters were mailed October 14, 2022. Owners may contact MBUSA customer service at 1-800-367-6372. MBUSA’s number for this recall is 2022080010.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.

 

Check if your Mercedes-Benz has a Recall

 


October 6, 2022

2022080010

Check Transmission Wiring Harness Connector

This is to notify you of a Recall Campaign Update to check the transmission wiring harness connector on 16,977 Model Year (“MY”) 2019-2022 4-Matic CLS-Class, E-Class, and GT-Class (257, 213, 238, and 290 platform ) vehicles. The recall campaign will be visible on the www.safercar.gov website and may generate questions from customers.  Affected VINs will be flagged in VMI as “OPEN” on October 6, 2022.

 

Issue

Mercedes-Benz AG (MBAG), the manufacturer of Mercedes-Benz vehicles, has determined that on certain E-Class (213 platform), E-Class Coupe/Cabriolet (238 platform), CLS (257 platform) and AMG GT 4-door (290 platform) 4Matic vehicles, the transmission wiring harness might not be routed according to specifications. Tension on the transmission wiring harness could lead to wire insulation pulling back from the electrical connector and as a result, water could enter the connector. Water ingress could lead to a short circuit and/or thermal overload if the vehicle’s ignition is off for longer periods of time. As a result, the risk of fire cannot be ruled out.  Before the issue occurs, the driver may be alerted to the condition by illumination of the yellow battery (electrical charge) indicator lamp and/or the “4Matic malfunction” warning message in the instrument cluster.

 

What We’re Doing

MBUSA will conduct a voluntary recall. An authorized Mercedes-Benz dealer will check the electrical connector on the affected vehicles and rework it, if necessary.

 

Parts

The remedy is available and can be performed.

Given this notice, it is a violation of Federal law for a dealer to sell or lease any new MY19-22 CLS-Class, E-Class, and GT-Class  vehicles in dealer inventory covered by this notification until the vehicle has been repaired. Once the remedy is available, the vehicles will be flagged as “OPEN” and Work Instructions will be available in Star TekInfo. Once the repair is complete the vehicle may be sold or leased.

Loaner and demonstrator vehicles may continue to be driven, but must not be retailed until repaired. As a matter of normal service process, please check for other repair measures that might be applicable to the vehicle(s).

Additionally, given this notice, it is a violation of Federal Law for car rental companies to rent new MY19-22 CLS-Class, E-Class, and GT-Class covered by this notification until the vehicle has been repaired.

 

Customer Notification Timeline

Customer letters will be mailed on or before October 14, 2022.

 


Check electrical connector on automatic transmission oil pan and rework or replace it, if necessary

Check/test procedure

  1. Remove lower rear engine compartment lining (under transmission).

For basic information, see: 

AR61.20-P-1105LWE for models 213 and 238,

AR61.20-P-1105FRX for model 290,

AR61.20-P-1105FR for model 257

 

  1. Disconnect electrical connector X279 (A, Figure 1) from right oil pan.

 

  1. Check insides of connector coupling on vehicle-side wiring harness A 290 540 99 14 (B, Figure 2) and transfer case wiring harness A 213 540 32 69 (C, Figure 2) for corrosion and other damage or noticeable problems.

 

a. If corrosion or moisture is detected, the vehicle-side wiring harness (A 290 540 99 14) must be repaired and the transfer case wiring harness (A 213 540 32 69) must always be replaced.

b. If OK, remove pins from vehicle-side wiring harness (B, Figure 2) using special tool W 220 589 01 99 63 (Figure 3) individually and one after the other, check for corrosion and damage, and reinsert pins.

 

Equivalent commercially available unpinning tools can also be used.

Do not remove all pins from the plug housing at the same time.

The pins must audibly “click” engage when reinserted.

No damage or noticeable problems may be visible.

No sealing elements may be damaged or melted at the cables.

Sealing elements must be properly crimped in the cable lug.

Sealing lip must be visible, see Figure 5 (OK image).

Figure 4 (not OK image) shows a defective sealing element.

 

Figure 4: (Sealing element not OK)

 

Figure 5: (Sealing element OK)

 

  1. Check green blind plugs (D, Figure 6) on rear of plug.

 

  1. A green blind plug that is not seated correctly must be pressed in further as per Figure 6 (OK image).

 

a. If pins, cables, seals, and plug housings show no damage or corrosion (OK): Carry out work procedure A.

b. If pins, cables, seals, or plug housings show damage or corrosion (not OK): Carry out work procedure B.

 

Work procedure A

  1. Attach new additional wiring harness bracket (E, Figure 7) with new screw to oil pan.  Threaded bushing is present in the oil pan.

 

  1. Remove retaining clamp including cable tie (arrow, Figure 8) from vehicle-side wiring harness.

 

  1. Attach retaining clamp with new preassembled cable tie (Figure 9) to new wiring harness bracket in direction of travel from rear up to end stop.

 

  1. Blow out connector coupling with compressed air.

 

  1. Connect connector (Figure 10) and allow secondary locking mechanism to engage.

Connector (Figure 10) may be connected only if absolutely dry.

 

  1. Attach wiring harness to new wiring harness bracket without tensile or compressive stress using new cable tie (Figure 10).

 

Work procedure B

In the case of damage or corrosion on pins, cables, seals, or plug housings on the vehicle and/or transfer case sides, they must be repaired/replaced as per the Check/test procedure 3 a.

When the repaired wiring harness is installed (repair of the vehicle-side wiring harness), the wiring harness on the transfer case must also be replaced without exception.

 

  1. Disconnect ground line of the 12 V on-board electrical system battery. For basic information, see AR54.10-P-0003*.

* Select the WIS document according to the vehicle model.

 

  1. Disconnect vehicle-side wiring harness in marked area and strip, (see Figure 11). Repair wiring harness using an end sleeve, see AR00.19-P-0100-09A.
  2. Attach additional holder as per work procedure A, see Figure 7.

 

  1. Insert repair wiring harness (A 290 540 99 14) and attach to new holder using cable tie without tensile or compressive stress, see Figure 10.

 

  1. Shorten repair wiring harness (A 290 540 99 14) to necessary length up to repair point (end sleeve).

Vehicle-side repair wiring harness must be installed without tensile or compressive stress.

 

  1. Repair wiring harness with end sleeve.

 

  1. Remove rear transmission crossbar.

Secure transmission against tilting.

 

  1. Unclip wiring harness on transfer case side from holder of automatic oil pan, unclip transfer case, and disconnect it from the variable transfer case control unit.

To disconnect control unit, press shield of exhaust system downward slightly.

 

  1. Replace wiring harness on transfer case side.

 

  1. Assemble in reverse order.

Should drops of water drip into plug housing during the work, they must be blown out with compressed air prior to connecting it.

Connector (Figure 8) may be connected only if absolutely dry.

 

Primary Parts Information

Qty. Part Name Part Number
1 Screw N 910143 006001
1 Bracket A 290 545 69 00
1 Cable tie A 006 997 35 90
As required (1) Repair kit (wiring harness incl. connector coupling) A 290 540 99 14
As required (2) Line connector (red) A 000 982 92 10
As required (3) Line connector (green) A 000 982 91 10
 As required (1)* Tape A 002 983 64 13
As required (1) Wiring harness transfer case A 213 540 32 69

* 1 container is to be used for approx. 10 vehicles.

Small parts such as screws, lock nuts, sealing rings, cable ties, fluids, sealant, etc. are not listed in the parts list. The required small parts are taken into account in the budgeting.

 


Amended Chronology of Defect/Noncompliance Determination Supplement’

ODI 22-00855-28172-10

In August 2019, MBAG was made aware of several cases in the U.S. in which customers received warnings via the vehicle instrument cluster regarding the 12V battery (electrical charge indicator) and/or the 4Matic system (“4Matic malfunction”).  MBAG investigated these cases and determined that corrosion of a transmission wiring harness electrical connector on triggered the messages in the instrument cluster. MBAG returned affected parts to Germany for inspection and testing regarding potential effects of corrosion in the electrical connector. At that time, MBAG’s investigation identified no risk of fire or other safety risks.

In August 2021, MBAG was made aware of field cases involving thermal events that occurred outside of the U.S.  MBAG launched extensive investigations into potential causes of these field cases.  As part of its investigation over the course of several months, MBAG evaluated the effects of different types of short circuits on the transmission wiring harness electrical connector. MBAG also compared the electrical resistance of corroded and non-corroded electrical connectors using computed tomography.

In the beginning of 2022, MBAG determined that production deviations in the routing and the length of the cable in the transmission wiring harness caused mechanical strain on the single-wire seal.  Separation of the seal could allow water to penetrate the electrical connector.  In April 2022, MBAG implemented a production change by using a longer harness and optimizing the harness position.  MBAG also developed an additional bracket to optimize the routing of the transmission wiring harness on potentially affected vehicles in the field.

MBAG continued further investigation to assess whether corrosion in the electrical connection could pose a fire or other safety risk.  Based on its investigation, MBAG identified forty-nine warranty claims in connection with this issue in the U.S. from February 13, 2019 to March 31, 2022.  MBAG determined that two such claims alleged thermal events involving the affected vehicle. On July 15, 2022, MBAG determined that a potential safety risk cannot be ruled out and decided to conduct a recall.

August 26, 2022 Amendment:
In August 2022, MBAG received feedback from individual markets that specific affected vehicles did not have the potentially affected wiring harness connector installed.  Thus, the scope of potentially affected vehicles was reassessed.  As a result, the scope of potentially affected vehicles was reduced.

Additionally, Model Year (“MY”) 2023 vehicles have been removed from the affected vehicle population as they have not been wholesaled.  These vehicles will be re-worked internally before entering the stream of commerce.

October 5, 2022 Amendment:
In September 2022, a service workshop outside the US reported to MBAG that a vehicle not included in the recall population had experienced similar warning light activation accompanied by a thermal event. Mercedes-Benz has investigated and determined that one vehicle option code had been inadvertently excluded from the potentially affected population of vehicles. Following this determination, MBAG conducted a thorough review to confirm and verify that all affected vehicles are included in the recall population. Based on that review, MBAG is confident that, with the addition of the 512 vehicles originally not included in the recall, it has identified the full population of vehicles that may have the defect. This report amends the scope of the recall to include the 512 vehicles previously not included in the recall population.

 


24 Affected Products

Vehicles

MAKE MODEL YEAR
MERCEDES-BENZ AMG CLS53 2019-2021
MERCEDES-BENZ AMG E53 2019-2023
MERCEDES-BENZ AMG GT43 2021-2023
MERCEDES-BENZ AMG GT53 2019-2023
MERCEDES-BENZ CLS450 2019-2023
MERCEDES-BENZ E450 2021-2023

 


20 Associated Documents

Manufacturer Notices(to Dealers,etc)

RCMN-22V533-0992.pdf 471.519KB

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Chronology of Defect

RMISC-22V533-8353.pdf 420.095KB

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Recall Acknowledgement

RCAK-22V533-7827.pdf 645.333KB

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Defect Notice 573 Report

RCLRPT-22V533-6872.PDF 220.294KB

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Recall 573 Report – August 26, 2022

RCLRPT-22V533-8022.PDF 217.236KB

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Amended Chronology of Defect/Noncompliance Determination Supplement

RMISC-22V533-7112.pdf 427.46KB

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Manufacturer Notices(to Dealers,etc)

RCMN-22V533-2817.pdf 471.799KB

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Recall 573 Report – September 8, 2022

RCLRPT-22V533-7078.PDF 245.773KB

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ISSUED Interim Owner Notification Letter(Part 577)

RIONL-22V533-0053.pdf 1232.967KB

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Manufacturer Notices(to Dealers,etc)

RCMN-22V533-6552.pdf 1162.909KB

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Remedy Instructions and TSB

RCRIT-22V533-0057.pdf 911.224KB

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Recall 573 Report – October 6, 2022

RCLRPT-22V533-7149.PDF 217.273KB

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Amended Chronology of Defect Supplement 22-00855-28172-10_V3

RMISC-22V533-6389.pdf 214.79KB

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Remedy Instructions and TSB

RCRIT-22V533-6766.pdf 1073.704KB

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Manufacturer Notices(to Dealers,etc)

RCMN-22V533-9777.pdf 1325KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-22V533-9424.pdf 1314.956KB

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Recall Quarterly Report #1, 2022-4

RCLQRT-22V533-8743.PDF 211.15KB

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Recall Quarterly Report #2, 2023-1

RCLQRT-22V533-2176.PDF 211.254KB

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Recall Quarterly Report #3, 2023-2

RCLQRT-22V533-5165.PDF 211.344KB

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Recall Quarterly Report #4, 2023-3

RCLQRT-22V533-4266.PDF 211.584KB

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22V533&docType=RCL

 


 

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