BMW 540I Recalls & Complaints by Model Year
NHTSA lists 23 safety recalls and 249 owner complaints across 23 model years of the BMW 540I (1989–2025). The most-complained-about year is 2000.
Pick your BMW 540I model year
| Model year | Recalls | Complaints |
|---|---|---|
| 2025 BMW 540I | 0 | 1 |
| 2024 BMW 540I | 1 | 5 |
| 2023 BMW 540I | 1 | 5 |
| 2022 BMW 540I | 1 | 6 |
| 2021 BMW 540I | 6 | 9 |
| 2020 BMW 540I | 5 | 3 |
| 2019 BMW 540I | 1 | 11 |
| 2018 BMW 540I | 2 | 31 |
| 2017 BMW 540I | 1 | 20 |
| 2003 BMW 540I | 2 | 7 |
| 2002 BMW 540I | 2 | 12 |
| 2001 BMW 540I | 4 | 15 |
| 2000 BMW 540I | 2 | 31 |
| 1999 BMW 540I | 1 | 22 |
| 1998 BMW 540I | 1 | 26 |
| 1997 BMW 540I | 0 | 27 |
| 1995 BMW 540I | 2 | 10 |
| 1994 BMW 540I | 4 | 8 |
| 1993 BMW 540I | 1 | 0 |
| 1992 BMW 540I | 1 | 0 |
| 1991 BMW 540I | 1 | 0 |
| 1990 BMW 540I | 1 | 0 |
| 1989 BMW 540I | 1 | 0 |
What BMW 540I owners complain about
Across all model years, owners have filed 249 complaints with NHTSA. The 2000 model year has the most, with 31.
All BMW 540I recalls (23)
Every NHTSA safety campaign that lists a BMW 540I, most recent first, with the model years each one covers.
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Driveshaft (power train)
BMW of North America, LLC (BMW) is recalling certain 2022-2026 840i, 840i xDrive, 2021-2023 540i, 540i xDrive, M550i xDrive, and 2024-2026 750e xDrive vehicles. The connection between the driveshaft and the rear differential may become damaged, possibly resulting in a loss of power to the rear wheels or a vehicle rollaway.
Remedy: Dealers will inspect the connection between the driveshaft and rear axle differential, and apply adhesive or replace the driveshaft and rear axle differential, as necessary, free of charge. Owner notification letters…
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Electronic stability control (esc): control module and service brakes, hydraulic: control unit/module
BMW of North America (BMW) is recalling certain 2023-2024 X1, 2024-2025 X5, 2025 X6, 2023-2025 X7, 740i, 760i, 2024 XM, 530i, 540i, i7, 750e, X2, 2024-2025 i5, 2024 Rolls Royce Spectre, 2025 MINI Countryman S ALL4, JCW Countryman ALL4, and 2025 MINI Hardtop 2 Door (Cooper, Cooper S) vehicles. Please refer to the recall report for the…
Remedy: Dealers will replace the integrated brake system, free of charge. Owner notification letters were mailed November 13, 2024. Owners can contact BMW Customer Service at 1-800-525-7417.
Model years: 2024
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Engine
BMW of North America, LLC (BMW) is recalling certain 2020 M340i, M340i xDrive, 540i, 540i xDrive, X3 M40i, 2020-2021 X4 M40i, 745Le xDrive, 2019-2021 Z4 M40i, and 2020-2021 Toyota Supra vehicles. During engine start, the engine management software may cause loss of braking assist. Full mechanical braking (without assist) remains…
Remedy: Dealers will update the engine management software, free of charge. Owner notification letters were mailed on September 17, 2021. Owners may contact BMW customer service at 1-800-525-7417.
Model years: 2020
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Seat belts
BMW of North America, LLC (BMW) is recalling certain 2021 2 Series (230i, 230i xDrive, M240i, M240i xDrive), 330e, 330e Xdrive, 4 Series Coupe (430i, 430i xDrive, M440i xDrive) M4 Coupe, M4 Competition Coupe, BMW 4 Series Convertible (430i, M440i), BMW X1 sDrive28i, xDrive28i, 2 Series Gran Coupe (228i, 228i xDrive, M235i xDrive), M2…
Remedy: Dealers will inspect the seat belt retractors (including the seat belts) and, if necessary, replace the retractors, free of charge. Owner notification letters were mailed on September 3, 2021. Owners may contact BMW…
Model years: 2021
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Software (back over prevention) and camera (back over prevention)
BMW of North America, LLC (BMW) is recalling certain 2019-2021 X3 sDrive30i, X3 xDrive30i, X3 M40i, X3M, X4 xDrive30i, X4 M40i, M550i, X4M, X5 sDrive40i, X5 xDrive40i, X5 xDrive50i, X5M, X5 M50i, X7 xDrive40i, X7 xDrive50i, X7 M50i, Alpina XB7, 330i, 330i xDrive, M340i, M340i xDrive, and 8 Series Coupe, Convertible and Grand Coupe,…
Remedy: BMW will notify owners, and dealers will inspect the rearview camera software and update it if necessary, free of charge. The recall began April 16, 2021. Owners may contact BMW customer service at 1-800-525-7417.
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Driveshaft (power train)
BMW of North America, LLC (BMW) is recalling certain 2020-2021 530i xDrive, 540i xDrive and 2021 740Li xDrive vehicles. The output shafts (left/right) which transfer power from the driveshaft to the rear wheels may break due to a heat treatment error during supplier production.
Remedy: BMW will notify owners, and dealers will replace the output shaft(s), free of charge. The recall began March 24, 2021. Owners may contact BMW customer service at 1-800-525-7417.
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12v/24v/48v battery (electrical system)
BMW of North America, LLC (BMW) is recalling certain 2021 M340i xDrive, M440i xDrive Coupe, 530i, 530i xDrive, 540i, 540i xDrive, 740Li, 740Li xDrive, 840i Gran Coupe, 840i xDrive Gran Coupe, X5 sDrive40i, X5 xDrive40i, X6 sDrive40i, X6 xDrive40i, and X7 xDrive40i vehicles. The connection between the 48-Volt battery and the…
Remedy: BMW will notify owners, and dealers will inspect the connection between the 48-Volt battery and the starter-generator assembly, replacing it if necessary, free of charge. The recall is expected to begin April 12, 2021.…
Model years: 2021
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Camera (back over prevention)
BMW of North America, LLC (BMW) is recalling certain 2020-2021 X3 sDrive 30i, X3 xDrive 30i, X3M 40i, X3 xDrive 30e, X4 xDrive 30i, X4M 40i, 530i, 540i, 540i xDrive, M550i xDrive, M5, 550e, 550e xDrive, and 550e iPerformance vehicles. A small portion of the rearview image may be slightly obscured. As such, these vehicles fail to comply…
Remedy: BMW will notify owners, and dealers will inspect and, if necessary, program the rearview camera with updated software. The recall began November 18, 2020. Owners may contact BMW customer service at 1-800-525-7417.
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Air bags and 2 other components
BMW of North America, LLC (BMW) is recalling certain 2017 530i, 530i xDrive, 540i and 540i xDrive and 2017-2018 530e xDrive vehicles. Prior exposure to excessive levels of humidity within the driver and passenger head air bag inflators may affect the proper deployment of the head air bags.
Remedy: BMW will notify owners, and dealers will replace the left or right head air bag, free of charge. The recall began June 24, 2020. Owners may contact BMW customer service at 1-800-525-7417.
Model years: 2017
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Camera (back over prevention)
BMW of North America, LLC (BMW) is recalling certain 2018 540d, 2018-2020 530i, 530i xDrive, 540i, 540i xDrive, M550i xDrive, M5, 530e, 530e xDrive, X3 sDrive, X3 xDrive, X3 M40i, X3 M, and 2019-2020 X4 xDrive, X4 M40i, X4 M, X7 xDrive, X7 M50i, 740Li, 740Li xDrive, 750Li, 750Li xDrive, 8 Series Convertible and Coupe 840i, 840i xDrive,…
Remedy: BMW will notify owners, and dealers will update the back-up camera software, free of charge. The recall began November 8, 2019. Owners may contact BMW customer service at 1-800-525-7417 or Rolls-Royce at…
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Inflator module (air bags) Do not drive
BMW of North America, LLC (BMW) is recalling certain model year 2000-2003 525i Sedan, 530i Sedan, 540i Sedan, 2001-2003 525i Sports Wagon and 540i Sports Wagon vehicles, and 2000-2004 X5 SAV 3.0i, X5 SAV 4.4i, and X5 SAV 4.6is vehicles. This recall affects certain vehicles where the original steering wheel has been replaced with the…
Remedy: Owners are advised not to drive their vehicles until the vehicle has been remedied. BMW will notify owners, and dealers will inspect the vehicle for an optional sports steering wheel with an affected inflator. Dealers…
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Engine (engine and engine cooling)
BMW of North America, LLC (BMW) is recalling certain 2018 BMW 540d xDrive vehicles. The crankshaft sensor may be equipped with incorrect firmware, preventing the sensor from properly processing input from the crankshaft reluctor ring, possibly resulting in a vehicle stall. On September 12, 2018, BMW expanded the recall to a total of…
Remedy: BMW will notify owners, and dealers will replace the crankshaft sensor, free of charge. The recall began September 6, 2018. Owners may contact BMW customer service at 1-800-525-7417.
Model years: 2018
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Inflator module (air bags) Do not drive
BMW of North America, LLC (BMW) is recalling certain model year 2002-2005 325i, 325xi, 330i, and 330xi Sedans, and 325xi and 325i Sportswagons, 2002-2006 330Ci, 325Ci, and M3 Convertibles and 325i, 330i, and M3 Coupes, 2002-2003 M5, 540i, 525i Sedan, and 530i Sedans, and 540i and 525i Sportswagons, and 2003 X5 3.0i and 4.4i Sports…
Remedy: Owners are advised not to drive their vehicles until the vehicle has been remedied. BMW will notify owners, and dealers will replace the front driver air bag module, free of charge. The recall began Aug 2016. Owners…
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Air bags: sensor/control module-inactive
On certain passenger vehicles, a microprocessor in the air bag control module, which activates the front air bags, the side air bags, the front seat safety belt pretensioners, and the battery safety terminal, may have a malfunction that could lead to an unintended activation of one or more of these components.
Remedy: Dealers will replace the air bag control module. Owner notification began november10, 2003. Owners should contact BMW at 1-800-831-1117.
Model years: 2001
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Fan (engine and engine cooling)
On certain passenger vehicles, the engine auxiliary/cooling fan operation, including variable speed, is electronically controlled. Failure of the fan motor can cause the electrical circuitry of the fan control unit to overload and fail, causing the fan to stop operating.
Remedy: Dealers will replace the fan. Owner notification began september 28, 2001. This is a supplement to a recall that began during september 2001 (see recall campaign 01v206). Owners who take their vehicles to an authorized…
Model years: 2001
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Fan (engine and engine cooling)
Vehicle description: passenger vehicles. The engine auxiliary/cooling fan operation, including variable speed, is electronically controlled. Failure of the fan motor can cause the electrical circuitry of the fan control unit to overload and fail, causing the fan to stop operating.
Remedy: Dealers will replace the fan. Owner notification began september 28, 2001. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable…
Model years: 2001
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Switch (exterior lighting)
Vehicle description: passenger vehicles. The brake lamps in these vehicles are controlled by a switch activated by the movement of the brake pedal. This switch could fail internally, causing it to remain either in the "brake lamps off" position or in the "brake lamps on" position.
Remedy: Dealers will inspect and, if necessary, replace the existing brake lamp switch with an improved switch.
Model years: 2000
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Cables (electrical system)
Vehicle description: passenger vehicles. The thickness of the main positive electrical cable (generator to starter) insulation is less than specified, making it susceptible to being abraded or cut by the clip that secures the cable to the generator.
Remedy: Dealers will apply a thickness of insulating tape to the cable in the area of the clip, and install a revised clip.
Model years: 1999
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Cooling system (engine and engine cooling)
Vehicle description: passenger vehicles. A malfunction or failure of a coolant system component, such as a thermostat, water pump, or fan belt, can result in significantly increased coolant temperature and system pressure. If the indications of a critical overheating condition is not noticed by the driver, it is possible that damage to,…
Remedy: Dealers will install a new design radiator cap to control pressure and provide greater coolant overflow in the event of overheating.
Model years: 1989, 1990, 1991, 1992, 1993, 1994, 1995
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Differential unit (power train)
Vehicle description: passenger vehicles. The differential pinion shaft within the differential case assembly was produced without the appropriate surface hardening. This can result in the shaft experiencing premature wear.
Remedy: Dealers will replace the entire differential assembly.
Model years: 1998
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Vehicle speed control
The cruise control and throttle cables are attached to the same throttle valve actuating lever at the throttle housing. It is possible that the plastic bushing on either cable could break due to environmental influences coupled with vibration. If the bushing breaks, the outer cable housing can separate from the bushing. In this case,…
Remedy: Dealers will install a spring steel clip on the outer tube of each cable in the area of the adjusting screw and plastic bushing. The clip is designed to prevent the outer tube from dislodging from the bushing.
Model years: 1994, 1995
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Switch (exterior lighting)
The brake light switch can fail allowing the switch to remain in the "brake lights off" position or in the "brake lights on" position.
Remedy: Dealers will replace the existing brake light switch with a newly designed switch.
Model years: 1994
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Power window devices and controls (visibility)
The remote activation device can close windows and sunroof from a distance greater than the maximum (6 meters) permitted by FMVSS no.118, "power operated window systems."
Remedy: Replace the inside rear view mirror which has the activation receiver with one whose receiver will control the door locking and theft alarm, but will not permit remote operation of the windows and sunroof.
Model years: 1994
Other BMW models
- X53,154 complaints
- 328I2,578 complaints
- X32,004 complaints
- 325I1,386 complaints
- Z41,281 complaints
- 3 Series843 complaints
- 528I835 complaints
- 330I815 complaints
Source: NHTSA recall and complaint databases and EPA fuel economy data, October 2026. Complaint counts are owner reports to NHTSA, not verified defects. Recall counts are safety campaigns that list this model year; whether a particular car was already repaired depends on its VIN. How this data is compiled.