Munich – Jan. 31, 2019 – BMW has issued a recall for its M3 and M4 models, to counter a potentially dangerous fault within the vehicles’ drive shafts. According to a company statement reported by Car Advice, the vehicles requiring inspection and repair were sold in Australia and noted by that country’s product safety monitor. The organization with recall authority in the U.S., the National Highway Traffic Safety Administration, has been inactive for much of January due to the government’s funding shutdown, thus making it unclear if a similar recall will affect U.S. BMW owners.

The vehicles involved are all sedans from the 2016 model year. The M3, M4 and M4 convertible are all affected by the recall and according to the announcement, these vehicles exist in very small quantities in Australia. With 97 vehicles affected, the M3 is the most popular of the three types. There are 71 of the hardtop M4, with only 10 of the convertible M4 recorded.

The process of recalling the vehicles shows that automakers follow procedure even when the number of cars in question is relatively small in a particular territory. Recent actions by specialist carmakers such as Maserati show attention being paid to models that were not made or exported in mass quantities.

The Defect

According to the company’s announcement, the potentially dangerous problem leading to the recent action is located within the affected vehicles’ drive shafts. The shafts on these cars are made of carbon fiber and contain two internal components – the three-hole flange and the pushing piece. The company questioned whether the pieces within the drive shaft will hold up over time and usage over the lifespan of the cars. If these parts were not made with “sufficient long-term durability”, the pushing piece could end up pulled out of the drive shaft, limiting the vehicle’s torque to the rear wheels. Such a lack of torque may may increase the risk of a collision, leading to the necessity of a recall.

Timeline of Events

The announcement from BMW did not clarify several pieces of information about the recall underway, such as how it was discovered or when. The vehicles involved all originate from the 2016 model years, but the notice was not issued until late January 2019. The press materials did not mention whether the fault was discovered as part of an inspection, due to an actual incident on the road or in a laboratory test. Furthermore, no connection to cars from outside of the Australian market was discussed.

The Solution

The statement announcing the recall was similarly quiet about what exactly the fix to the problem will entail. Drivers were urged by Car Advice to get in touch with their respective BMW dealers and receive repairs for the drive shaft free of charge. Due to the nature of the problem, with parts potentially not tough enough to stand up to long-term use, it appears likely those component will be replaced with stronger replacement parts, thus making the drive shaft safe for continued use, no matter how long the sedans are on the road.

Laguna Hills, CA – November 7, 2018 – BMW of North America, LLC (BMW) is recalling certain models over fire risk. These vehicles are equipped with an Exhaust Gas Recirculation (EGR) module with an integrated cooler. If the EGR cooler leaks internally, the coolant can mix with diesel engine soot. The high EGR temperatures may result in these particles possibly smoldering and melting the intake manifold, which can increase the risk of a fire.

Included in this recall are: 

• 2013-2018 BMW 328d and 328d xDrive 

• 2014-2018 BMW 328d Sports Wagon and 328d xDrive Sports Wagon

• 2014-2016 BMW 535d and 535d xDrive

• 2015 BMW 740Ld xDrive

• 2015-2017 BMW  X3 xDrive28d SAV 

• 2014-2017 BMW X5 xDrive35d SAV 

The Defect

According to the NHTSA Recall Safety Report, approximately 12,781 Model Year 2013-2018 BMW 328d and 328d xDrive Diesel engine vehicles were equipped with an Exhaust Gas Recirculation (EGR) module that featured an integrated cooling component (“cooler”). Over time, this component could start to internally leak glycol coolant, because the recall component was not produced with sufficient long-term durability characteristics. During vehicle operation, if an internal coolant leak began inside the EGR cooler, the fluid could mix with normal diesel engine soot/sediment. This combination in the engine environment with high temperatures normally present might result in smoldering particles, which in very rare cases could lead to the melting of the intake manifold. In extreme cases, this could result in a possible fire. During vehicle operation, the driver may be alerted to this condition by one or more of the following: A warning symbol in the instrument cluster displaying a loss of engine coolant, a reduction in engine power, an unpleasant odor (exhaust gas), an unusual noise from the engine compartment, and/or smoke from the engine compartment.

Timeline of Events

On July 26, 2018, BMW submitted the required Part 579 report, to which NHTSA assigned “18F-137” as the Foreign Recall ID after BMW became aware of an issue in the Korean market. On September 5, 2018, BMW met with NHTSA to explain EGR system differences between vehicles in the U.S. market and vehicles in other markets. BMW provided a summary of U.S. field data including warranty claims, consumer complaints, and field reports which indicated coolant leak warnings, drivability concerns, or damage to the intake manifold. BMW also stated that it would continue to closely monitor the field. In October 2018, further in-depth analyses indicated that it was possible that one incident could be attributed to this issue. BMW decided to conduct a voluntary safety recall although at the time of the report, BMW was unaware of any accidents or injuries related to this issue.

The Solution

Owners will be notified by First Class mail and instructed to take their vehicle to an authorized BMW center to have the remedy performed at no cost. The EGR cooler will be inspected and, if necessary, replaced free of charge. If it is determined that the EGR cooler has internally leaked, the engine intake manifold will also be replaced. The EGR pipe connecting the cooler to the manifold will be cleaned. Owners who have replaced the EGR cooler at their own expense prior to the recall notification may be eligible for reimbursement according to BMW Group’s reimbursement plan. Notification to owners is planned to begin and end on December 17, 2018. Owners may also call the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153). The NHTSA Campaign Number for this recall is 18V-755.

Other BMW Recalls 

Some of these vehicles may have been a part of a recall in August of 2021, when BMW recalled vehicles over a risk of engine stalling caused by a high-pressure fuel pump that suffers from excessive wear. In addition, even vehicles with gasoline engines, such as the 328i station wagon, had problems with their fuel pumps in the past.  

• 2014 – 2018 BMW 328D
• 2015 – 2017 BMW X3
• 2014 – 2016 BMW 535D
• 2014 – 2018 BMW X5 
• 2015 BMW 740LD

The affected component in this recall is the BMW high-pressure fuel pump with part number 7810696 and 7283473

Is your vehicle a part of this recall?

This BMW recall includes more than 11,000 vehicles. To check for this and other BMW recalls, use MotorSafety’s free vehicle lookup tool.

Laguna Hills, CA – October 25, 2018 – BMW of North America, LLC (BMW) is recalling certain 2019 BMW X6 sDrive35i, X6 xDrive35i, X6 xDrive50i and X6M vehicles. Approximately 108 vehicles are suspected to have been manufactured with rear upper control arms that possibly have not been produced by the suppliers to acceptable specifications. This recall affects several different BMW models, and units recalled were produced between September 10 and September 20, 2018.

The Defect

According to the NHTSA Recall Safety Report, certain BMW vehicles may have been produced with a faulty part. The rear upper control arm’s pivot bolt may not have been properly hardened during supplier production, due to a failure in the production process. An arm that was not produced to specifications could break, which could then affect vehicle handling and control, increasing the risk of a crash.

Timeline of Events

On September 12, 2018, several damaged control arms were noticed during vehicle assembly. The supplier was contacted, who was able to determine that certain rear upper control arms may not have been properly hardened, and identify all potentially affected parts to generate a list that was the matched with vehicle assembly records. Approximately 108 vehicles were identified, and on September 21, 2018, BMW decided to conduct a voluntary safety recall. BMW has not received any reports of any accidents or injuries related to this issue.

The Solution

Owners will be notified by First Class mail and instructed to take their vehicle to an authorized BMW center to have both rear upper control arms replaced for free. As affected vehicles are covered by the BMW New Vehicle Limited Warranty program, there is no need for owners to cover the cost and no need for a reimbursement program. Notification to owners is planned to begin and end on November 12. Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153). The NHTSA Campaign Number for this recall is 18V680000.

Laguna Hills, CA – October 19, 2018 – BMW of North America, LLC (BMW) is recalling certain 2016-2017 BMW M3 Sedans, 2016-2017 BMW M4 and M4 GTS Coupes and 2017 BMW M4 Convertible vehicles due to potential driveshaft failure. The potential number of units affected by this recall is 2,661.

The Defect

According to the NHTSA Recall Safety Report, this safety recall involves an integral flange located in the driveshaft, which has insufficient long-term durability. Due to this defect, the connection between the driveshaft and the flange may loosen over time, to the point of separating completely.

Loss of connection between the driveshaft and the flange means that, then drive torque may no longer be transmitted to the rear wheels. Lack of drive torque results in a loss of propulsion, increasing the risk of a crash. The driver may be alerted by noise and/or vibration from underneath the vehicle, which may increase over time and indicates the need to take the car to a dealership.

Timeline of Events

On July 9, 2018, BMW was informed of field incidents involving the driveshaft of M3 Sedan, M4 Coupe, and M4 Convertible vehicles. Drivers of these vehicles reported hearing noise, noticing vibration, and, in some cases, experiencing a loss of power. BMW subsequently requested the drive shafts in order to carry out comprehensive inspection and analysis, considering factors such as vehicle age and mileage, engine power / torque, and operating and environmental conditions.

By late August, preliminary analyses suggested the integral driveshaft flange was the faulty part, and in September, further in-depth analyses were conducted taking into account vehicle construction, engine type, driveshaft design/build configuration history, and drive train geometry. Once individual case assessments were completed, these engineering analyses concluded that the integral flange may not have been produced with sufficient long-term durability characteristics during a specific production period, and separation from the drive shaft was a risk.

Driveshaft production records and vehicle manufacturing information were utilized to identify the quantity and production date range of potentially affected vehicles, and on October 4, 2018, BMW issued a voluntary safety recall. BMW has not received any reports or been made aware of any accidents or injuries related to this issue.

The Solution

The drive shaft, containing the integral flange, will be replaced. Owners will be notified by First Class mail and instructed to take their vehicle to an authorized BMW center to have the drive shaft replaced at no charge. This process typically takes several hours. Owners who have replaced the drive shaft at their own expense prior to the recall notification may be eligible for reimbursement according to BMW Group’s reimbursement plan. The recall is expected to begin December 3, 2018; owners will be notified and advised whether or not their local dealership has available parts for the repair. If not, a second letter will advise owners when parts become  Owners may contact BMW customer service at 1-800-525-7417.

Owners may also call the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153). The NHTSA Campaign Number for this recall is 18V-713.

Westwood, N.J. – July 26, 2018 – BMW of North America has recalled more than three dozen vehicles potentially equipped with defective front lower control arms, according to documentation submitted to the National Highway Traffic Safety Administration. The campaign affects multiple models produced between June 9 and June 11, 2018, including:

• 2018 BMW X-5 xDrive35i and xDrive50i sport utility vehicles.
• 2018 BMW X-5 xDrive35d sport utility vehicles.
• 2018 BMW X-6 sDrive35i sport utility vehicles.

The German automaker suspects just 3 percent of the models involved in the recall contain the defective parts.

The Defect

Affected vehicles could contain front lower control arms with insufficiently hardened pivot bolts prone to breakage. In the event that these components fail, the control arm may cease operation, leading to a sudden and sharp decline in vehicle handling functionality. The defect therefore poses a serious safety hazard to occupants. However, BMW has yet to receive reports connecting the problematic parts to any accidents or injuries.

Timeline of Events

On June 15, 2018, THK Rhythm Automotive Canada, the supplier of the control arms used in the recalled vehicles, contacted BMW and revealed that numerous units may not have been hardened properly due to a production error. Following this communication, the vendor conducted a review to see how many of the defective control arms were shipped to the vehicle manufacturer. After receiving this data, BMW evaluated its production records and pinpointed the vehicles that could have been equipped with the problematic control arms.

On June 21, 2018, the automaker launched a voluntary safety recall to address the issue. The company informed dealers of the forthcoming action June 28, 2018.

The Solution

BMW has directed dealers to replace the front lower control arms in affected vehicles free of charge, according to an NHTSA recall acknowledgement document. Owners should expect to receive further details about the recall via first-class mail Aug. 20, 2018. Those in need of assistance prior to the start of the campaign can speak with BMW customer service personnel by calling (800) 525-7417. Owners can also reach out to the NHTSA directly using the agency’s Vehicle Safety Hotline at (888) 327-4236.

Westwood, N.J. – July 3, 2018 – BMW of North America has recalled more than 50 vehicles potentially equipped with defective steering wheels, according to documentation submitted to the National Highway Transportation Safety Administration.

The campaign affects 2018-2019 BMW X-3 xDrive30i, sDrive30i and M40i sport utility vehicles produced between April 26, 2018, and May 2, 2018. The German automaker suspects one-quarter of the vehicles referenced in the action contain the defective parts.

The Defect

Affected models feature steering wheels with defective Active Lane Keeping Assistant sensors. In the event that these sensors fail, drivers may not be alerted when the steering wheel is unattended, increasing the likelihood of a collision. However, BMW has yet to receive reports connecting the problematic parts to any accidents or injuries.

Timeline of Events

On April 30, 2018, BMW’s steering wheel supplier reported that some previously installed assemblies may not have Active Lane Keeping Assistant functionality. Specifically, the sensors installed in the wheels were deemed incompatible with this advanced feature. The car company immediately initiated an engineering, during which time technicians performed field tests and confirmed the suppliers’ suspicions.

Following these findings, BMW reviewed its production records and cross-checked them with data from the parts vendor to determine the breadth of the issue. Then, on May 30, 2018, quality assurance personnel reviewed the matter and called for a voluntary safety recall.

BMW notified dealers of the forthcoming action June 6, 2018.

The Solution

The automaker has directed dealers to inspect and, if necessary, replace the steering wheels in affected vehicles free of charge, according to an NHTSA recall acknowledgment document. BMW intends to notify owners via first-class mail July 23, 2018. Those in need of assistance prior to the start of the recall campaign can speak with BMW customer service by calling (800) 525-7417. Owners can also reach out to the NHTSA directly using the agency’s toll-free Vehicle Safety Hotline at (888) 327-4236.