1998 BMW 540I
1 recalls, 28 complaints - 24 TSBs
98V142000 Jun 22, 1998
POWER TRAIN:DRIVELINE:DIFFERENTIAL UNIT
Defect Description
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.
Consequence
THIS CONDITION WILL CAUSE A NOISE FROM THE DIFFERENTIAL AND, ULTIMATELY, FAILURE OF THE SHAFT AND LOSS OF DRIVE.
Remedy
DEALERS WILL REPLACE THE ENTIRE DIFFERENTIAL ASSEMBLY.
Complaint Statistics
28 total complaints
1 injuries
Top Reported Components
| Component | Complaints |
|---|---|
| ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY | 7 |
| ENGINE AND ENGINE COOLING:ENGINE:GASOLINE | 3 |
| ENGINE AND ENGINE COOLING:COOLING SYSTEM | 3 |
| LATCHES/LOCKS/LINKAGES:TRUNK LID:LOCK | 2 |
| STRUCTURE:BODY:DOOR | 2 |
| ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:CATALYTIC CONVERTOR | 2 |
| ENGINE AND ENGINE COOLING | 2 |
| POWER TRAIN:CLUTCH ASSEMBLY | 1 |
| STEERING: STEERING WHEEL/HANDLE BAR | 1 |
| ENGINE AND ENGINE COOLING:COOLING SYSTEM:HOSES/LINES/PIPING/FITTINGS | 1 |
AIR BAGS
May 21, 2021
Incident date: May 17, 2021
While stopped (engine still running) at a gas station, the driver side airbag and driver side side curtain airbag both went off. The battery disconnect feature was also triggered. Very lucky I wasn't driving when this occurred.
1 injured
ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY
Jan 27, 2005
Incident date: Jan 24, 2005
WHITE STEAM WAS COMING FROM UNDER THE HOOD ONTO THE FRONT WINDSHIELD. THE STEAM WAS FOGGING THE WINDSHIELD, AND CAUSING POOR VISIBILITY WHILE DRIVING 50-55 MPH. CONSUMER WAS ABLE TO GET THE VEHICLE TO A REPAIR SHOP. DEALER INFORMED THE CONSUMER THAT THE UPPER NECK CONNECTOR OF THE RADIATOR HOSE BRO... Read more
ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY
Jan 6, 2005
Incident date: Feb 12, 2004
2ND CATASTROPHIC RADIATOR FAILURE. NOT A LEAK, THE NECK BREAKS OFF CAUSING IMMEDIATE LOSS OF COOLING. 1ST RADIATOR AT 45K, 2ND AT 92K. BASED ON OTHER'S EXPERIENCES, THIS IS VERY COMMON FOR THIS MODEL (AND EVEN LONGER LIFE THAN MANY). CAUSES LOSS OF VISION DUE TO AMOUNT OF STEAM RELEASED. LESS EXPERI... Read more
ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY
Jul 2, 2004
Incident date: May 2, 2004
I WAS DRIVING DOWN A BUSY STREET ONE EVENING AND AS I CAME TO A LIGHT, SMOKE STARTED COMING OUT OF MY HOOD. FORTUNATELY IT WAS IN THE EVENING AND TRAFFIC WAS LIGHTER THAN USUAL. I PULLED INTO A PARKING LOT OFF THE SIDE OF THE ROAD. HAVING KNOWN OTHERS THAT THIS HAS HAPPENED TO, I FIRST CHECKED TH... Read more
ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY
Mar 17, 2004
Incident date: Oct 20, 2003
PLASTIC NECK OF RADIATOR ON MY '98 BMW 540IA BROKE COMPLETELY AND SUDDENLY ON HIGHWAY. WHITE SMOKE CAME OUT UNDER THE HOOD. SAW TEMP GAUGE CLIMB UP RAPIDLY. PULLED OVER IMMEDIATELY. TOWED TO DEALERSHIP FOR REPAIR. NO ONE WAS HURT LUCKILY. *NM
ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY
Nov 10, 2003
Incident date: Nov 3, 2003
MULTIPLE COOLANT DEFECTS ON THE 1998 540. THE CAR HAS NOW HAD 3 RADIATORS, 3 THERMASTATS, WATER TUBE SEALS REPLACED TWICE, AND A WATER PUMP. THE COSTS HAVE BEEN OVER $3,500. THESE LEAKS ARE NOT JUST EXPENSIVE, THEY POSE A REAL DANGER TO CAUSING PERSONAL INJURY AND DAMAGE. THE FAILURE RATE IS KNO... Read more
ENGINE AND ENGINE COOLING
Nov 10, 2003
Incident date: Nov 3, 2003
MULTIPLE COOLANT DEFECTS ON THE 1998 540. THE CAR HAS NOW HAD 3 RADIATORS, 3 THERMASTATS, WATER TUBE SEALS REPLACED TWICE, AND A WATER PUMP. THE COSTS HAVE BEEN OVER $3,500. THESE LEAKS ARE NOT JUST EXPENSIVE, THEY POSE A REAL DANGER TO CAUSING PERSONAL INJURY AND DAMAGE. THE FAILURE RATE IS KNO... Read more
ENGINE AND ENGINE COOLING:COOLING SYSTEM
Nov 10, 2003
Incident date: Nov 3, 2003
MULTIPLE COOLANT DEFECTS ON THE 1998 540. THE CAR HAS NOW HAD 3 RADIATORS, 3 THERMASTATS, WATER TUBE SEALS REPLACED TWICE, AND A WATER PUMP. THE COSTS HAVE BEEN OVER $3,500. THESE LEAKS ARE NOT JUST EXPENSIVE, THEY POSE A REAL DANGER TO CAUSING PERSONAL INJURY AND DAMAGE. THE FAILURE RATE IS KNO... Read more
SUSPENSION:FRONT:WHEEL BEARING
Sep 26, 2003
Incident date: Jul 2, 2003
DRIVER-SIDE FRONT WHEEL BEARING MAKES NOISE WHEN WHEEL SPINS FREELY. THIS WAS REPORTED SEVERAL TIMES TO DEALER IN PAST. DEALER REPLACED PASSENGER-SIDE FRONT BEARING ! DRIVER-SIDE BERAING STILL NOISY. WAITING FOR COMPLETE FAILURE TO PROVE DEALER WRONG. FRONT WHEEL BEARINGS ARE MARGINALLY DESIGNED ... Read more
ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY
Sep 26, 2003
Incident date: Apr 26, 2003
ENGINE COOLING RADIATOR HOSE FITTING BROKE OFF. LOST ALL COOLANT ON HIGHWAY. DEALER REPLACED RADIATOR UNDER WARRANTY AND STATED IT IS COMMON FAILURE ON 540I BMW DUE TO PLASTIC PARTS NOT STONG ENOUGH TO RESIST TEMPERATURE. WELL DOCUMENTED ON PRIVATE WEB SITES.
VISIBILITY:SUN/MOON ROOF ASSEMBLY
Sep 25, 2003
Incident date: Nov 28, 2001
SUNROOF FAILED AND MOVING UP AND DOWN ON BUMPS. DEALER REPLACED SLIDING MECHANISM. STILL RATTLES AND DOESN'T FUNCTION PROPERLY. DEALER DECLINES TO FIX UNDER WARRANTY. DOOR SEALS SQUEEK. DEALER LUBRICATED THEM. SILL SQUEEK AFTER A FEW DAYS. ALL CUP HOLDERS BROKEN. DEALER REPLACED THEM.
ENGINE AND ENGINE COOLING
Sep 25, 2003
Incident date: May 29, 2002
ENGINE IDLES ROUGH AND STALLS WHILE DRIVING. DEALER REPLACED FAULTY CAMSHAFT SENSOR UNDER WARRANTY.
ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:CATALYTIC CONVERTOR
Sep 25, 2003
Incident date: Nov 19, 2002
ENGINE DOESN'T REV UP ABOVE 4500 RPMS AND MISFIRES. ENGINE CHECK LIGHT ON. DEALER REPLACED ONE OF TWO CATALYTIC CONVERTERS UNDER WARRANTY. ACCORDING TO PRIVATE CLUBS ABD WEB SITES OF BMW OWNERS, 540I CAT CONVERTERS LAST 50KMILES ONLY.
LATCHES/LOCKS/LINKAGES:TRUNK LID:LOCK
Sep 25, 2003
Incident date: Mar 5, 2002
TRUNK LATCH FAILED. TRUNK STAYS OPEN. DEALER REPLECED ACTUATOR.
PARKING BRAKE:CONVENTIONAL:MECHANICAL
Sep 25, 2003
Incident date: Sep 24, 2001
BOTH SUN VISORS CRACKED ALONG WELD SEAM. REPLACED BY DEALER. TEMPERATURE CONTROL SWITCHE COVERS BROKEN. REPLACED BY DEALER. NOTICED THE DESIGN OF NEW COVERS IS DIFFERENT AND ELIMINATES RISK OF FAILURE. PARKING BRAKE DOESN'T HOLD. DEALER ADMITS BAD DESIN AND TRIED DIFFERENT SHOES WITHOUT SUCCESS IN... Read more
ENGINE AND ENGINE COOLING:COOLING SYSTEM:HOSES/LINES/PIPING/FITTINGS
Apr 29, 2003
TECHNICIANS TOLD ME THIS WAS A COMMON PROBLEM SINCE MANUFACTURER SWITCH TO PLASTIC RADIATORS. THE UPPER HOSE FITTING BROKE OFF THE RADIATOR. *PH *JB **DIMSII IVOQ ENTRY POSTED AFTER 12/12/02 CUT OVER TO ARTEMIS**762585
ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY
Jan 14, 2003
Incident date: Oct 15, 2002
RADIATOR NECK SHEARED OFF WITHOUT WARNING WHILE MY WIFE WAS DRIVING ON FREEWAY. CAUSED IMMEDIATE LOSS OF COOLANT AND EMERGENCY STOP. CAR HAD TO BE TOWED.
ENGINE AND ENGINE COOLING:COOLING SYSTEM
Nov 13, 2002
Incident date: Jan 8, 2001
SECOND RADIATOR FAILURE AT 56,254 MILES IN 10/19/2001 CAUSED POOR VISIBILITY. DT
ENGINE AND ENGINE COOLING:COOLING SYSTEM
Nov 5, 2002
Incident date: Oct 14, 2002
RADIATOR FAILED WITHOUT WARNING. STEAM OBSCURRED VISION. DT
ENGINE AND ENGINE COOLING:ENGINE:GASOLINE
Mar 14, 2000
ENGINE ENTERMITTENTLY STALLED WHEN THE CLUTCH IS DEPRESSED WHILE DRIVING AND IS RELATED TO AN INTERMITTENT LOW RMP ENGINE MALFUNCTION. YH
STRUCTURE:BODY:DOOR
Jan 2, 2000
HANDLES (2 INCIDENTS) BROKE OFF IN THE NORMAL ACTION OF OPENING THE DOOR. NOTHING EXTRAORDINARY ABOUT THE SITUATION. SEEMS A VERY CHEAP COMPONENT ON A VERY SAFETY CONSCIOUS VEHICLE. *AK
STEERING: STEERING WHEEL/HANDLE BAR
Oct 7, 1999
Incident date: May 1, 1998
STEERING WHEEL COLUMN ADJUSTMENT FAILS. MAKING ADJUSTMENT OF STEERING WHEEL AND VEHICLE SAFE TO OPERATE. STEERING WHEEL AND FRONT SEAT ADJUMENTS FAIL TO OPERATE FORCING OPERATOR TO DRIVE WITHOUT ABILITY TO ADJUST STEERING WHEEL OR SEAT. HAS FORCED ME TO ABANDON VEHICLE.
ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:CATALYTIC CONVERTOR
Aug 30, 1999
Incident date: Oct 1, 1998
CATALYTIC CONVERTER SYSTEM FAILED. *YC
ENGINE AND ENGINE COOLING:ENGINE:GASOLINE
Aug 21, 1999
Incident date: Aug 20, 1999
DRASTIC ENGINE POWER LOSS 4-5000RPM. THIS PROBLEM IS WELL DOCUMENTED ON HTTP://WWW.BIMMER.ORG/5SERIES/MESSAGES/. DEALER HAS NO KNOWLEDGE.
STRUCTURE:BODY:DOOR
Jul 30, 1999
Incident date: Oct 1, 1998
INTERIOR DOOR LATCH/HANDLE BROKEN AND FELL OFF OF DOOR, MUST BE OPENED FROM THE EXTERIOR. MJS
LATCHES/LOCKS/LINKAGES:TRUNK LID:LOCK
Jun 2, 1999
Incident date: Jul 1, 1998
TRUNK LATCH FAILED. *YC
POWER TRAIN:CLUTCH ASSEMBLY
Feb 17, 1999
Incident date: Aug 16, 1998
I HAVE DRIVE STANDARD TRANSMISSIONS FOR OVER 40 YEARS, I HAVE NEVER HAD A CLUTCH PROBLEM UNTIL A PURCHASED A '95 540I (KNOW FOR POORLY DESIGNED CLUTCHES, PARTICULARLY THE PRESSURE PLATE). I BOUGHT THIS NEW '98 WITH HOPES THE PROBLEM WAS SOLVED, NO SUCH LUCK. IF I HAD THE FAILURE ON A MAJOR HIGHWAY... Read more
ENGINE AND ENGINE COOLING:ENGINE:GASOLINE
Jan 20, 1999
Incident date: Jan 10, 1998
CONSUMER MAY BE DRVING AT ANY GIVEN SPEED. WHEN HE BEGINS TO SLOW DOWN OR IF HE DOWNSHIFTS AND TURNS, ENGINE WILL SHUT DOWN, CAUSING LOSS OF STEERING AND BRAKING CONTROL. BMW DEALERSHIPS CANNOT FIND A CAUSE. *AK
EPA Fuel Economy, 1998 BMW 540I
| Trim / Engine | City MPG | Highway MPG | Combined MPG | Fuel Type | Annual Fuel Cost |
|---|---|---|---|---|---|
| 4.4L 8-cyl, Automatic 5-spd (Rear-Wheel Drive) | 16.0 | 22.0 | 18.0 | Regular | $3,450 |
| 4.4L 8-cyl, Manual 6-spd (Rear-Wheel Drive) | 14.0 | 22.0 | 16.0 | Regular | $3,900 |
CO2 Emissions: -1.0 g/mile (Compact Cars)
Source: U.S. Environmental Protection Agency (EPA). Actual fuel economy may vary based on driving conditions.
Technical Service Bulletins, 1998 BMW 540I
24 manufacturer communications from 18 unique bulletins. TSBs describe known problems and recommended fixes from the manufacturer.
Most Affected Components
| Component | Bulletins |
|---|---|
| 140000 AIR BAGS | 6 |
| 110000 ELECTRICAL SYSTEM | 3 |
| 980000 UNKNOWN OR OTHER | 2 |
| 350000 EQUIPMENT | 2 |
| 045200 SERVICE BRAKES, AIR:DISC:PADS | 1 |
| 061000 ENGINE AND ENGINE COOLING:ENGINE | 1 |
| 030000 SERVICE BRAKES, HYDRAULIC | 1 |
| 070000 FUEL SYSTEM, GASOLINE | 1 |
B510819
Jan 16, 2024
133000 VISIBILITY:POWER WINDOW DEVICES AND CONTROLS
The basic conditions for initializing the power windows are not met.
B510819
Jan 16, 2024
110000 ELECTRICAL SYSTEM
The basic conditions for initializing the power windows are not met.
B013118
Apr 1, 2019
140000 AIR BAGS
TAKATA AIR BAG RECALL-RELATED SHORT-TERM ALTERNATE TRANSPORTATION AND CONSEQUENTIAL REPAIRS This Service Information bulletin supersedes SI B01 31 18 dated October 2018.
B013118
Apr 1, 2019
140000 AIR BAGS
TAKATA AIR BAG RECALL-RELATED SHORT-TERM ALTERNATE TRANSPORTATION AND CONSEQUENTIAL REPAIRS This Service Information bulletin supersedes SI B01 31 18 dated October 2018.
B011618
Jan 1, 2019
140100 AIR BAGS: AIR BAG/RESTRAINT CONTROL MODULE
TAKATA CLASS ACTION SETTLEMENT. CUSTOMER SUPPORT PROGRAM. FRONT DRIVER SIDE AIRBAG MODULES.
B011618
Jan 1, 2019
140000 AIR BAGS
TAKATA CLASS ACTION SETTLEMENT. CUSTOMER SUPPORT PROGRAM. FRONT DRIVER SIDE AIRBAG MODULES.
B650916
Nov 1, 2018
350000 EQUIPMENT
Radio / Navigation / Head Unit Identification Guide
B011618
Oct 1, 2018
140000 AIR BAGS
For the above-referenced vehicles with driver?s side airbag modules, BMW of North America, LLC (?BMW NA?) will provide a Customer Support Program as outlined in the Takata Settlement Customer Support Program Overview attachment. This ?comp
B011618
Oct 1, 2018
110000 ELECTRICAL SYSTEM
For the above-referenced vehicles with driver?s side airbag modules, BMW of North America, LLC (?BMW NA?) will provide a Customer Support Program as outlined in the Takata Settlement Customer Support Program Overview attachment. This ?comp
B080119
Feb 1, 2018
140000 AIR BAGS
In an effort to improve the completion rate on Takata air bag recall affected vehicles; BMW NA has expanded the BMW Ultimate Rewards platform to include a new Recall Support page. This page will allow IRFs to check their customers VINs for
B122817
Dec 1, 2017
060000 ENGINE AND ENGINE COOLING
SERVICE ACTION: PROGRAM DME (FOR O2 SENSORS): Due to DME software error, the following oxygen sensors plausibility fault codes may be stored in DME 5.2.1 control module:
B122817
Dec 1, 2017
118000 ELECTRICAL SYSTEM:SOFTWARE
SERVICE ACTION: PROGRAM DME (FOR O2 SENSORS): Due to DME software error, the following oxygen sensors plausibility fault codes may be stored in DME 5.2.1 control module:
B122917
Dec 1, 2017
355200 EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL
SERVICE ACTION: PROGRAM DME: The incorrect dataset could be programmed into DME 5.2.1 control module.
121999
Jun 1, 1999
110000 ELECTRICAL SYSTEM
INFORMATION ON PROGRAMMING ME7.2 ENGINE CONTROL MODULES WITH CD 18. *TT
651998
Feb 1, 1999
353400 EQUIPMENT:ELECTRICAL:RADIO/TAPE DECK/CD ETC.
SUBJECT PERTAINING TO DSP AMPLIFIER SWITCHING TO
65 02 98
Mar 1, 1998
061100 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE
ENGINE CRANKS, BUT WILL NOT START. *YC
16 01 98
Mar 1, 1998
070000 FUEL SYSTEM, GASOLINE
INFORMATION ON EVAPORATIVE EMISSION CONTROL AND FUEL FILLER CAP / FILLER DOOR LABELS. *YC
04 01 98
Feb 1, 1998
980000 UNKNOWN OR OTHER
SUBJECT ON TANK VENTILATION LEAK COUPLERS. *YC
34 01 98
Feb 1, 1998
030000 SERVICE BRAKES, HYDRAULIC
EXPERIENCING AN INTERMITTENT MOMENTARY EVENT WHERE THE BRAKE PEDAL DOES NOT IMMEDIATLELY RETURN. MODELS BUILT PRIOR TO 3/97 *DB*YC
16 04 97
Feb 1, 1998
061000 ENGINE AND ENGINE COOLING:ENGINE
NEW EVAPORATIVE (CHARCOAL) CANISTER PURGE LINE. ALL E38 AND E39 MODELE INTRODUCED INTO PRODUCTION APPROXIMATELY 3/97 *DB*YC
62 01 98
Feb 1, 1998
045200 SERVICE BRAKES, AIR:DISC:PADS
CONDITION WITH BRAKE PAD WARNING STAYS ILLUMINATED AFTER BRAKE PAD REPLACEMENT. *YC
72 08 97
Feb 1, 1998
140000 AIR BAGS
VARIOUS INFORMATION REGARDING DEACTIVATION OF AIRBAGS. *YC
66 02 97
Jan 1, 1998
980000 UNKNOWN OR OTHER
INFORMATION AND PROCEDURES ON THE GARAGE DOOR OPENER. *YC
04 17 97
Jan 1, 1998
350000 EQUIPMENT
SITUATION WITH THE TENSION ROD TEST GAUGE. *YC
BMW 540I - All Years Overview
Complete safety history for the BMW 540I across all model years (1989, 2024).
38
Total Recalls
340
Total Complaints
0
Investigations
11
Reported Crashes
8
Reported Fires
0
Reported Deaths
BMW 540I - Year by Year
Compare recalls and complaints across model years. Click any year to see full details.
| Year | Recalls | Complaints | |
|---|---|---|---|
| 2025 | 0 | 1 | View |
| 2024 | 1 | 10 | View |
| 2023 | 0 | 7 | View |
| 2022 | 0 | 7 | View |
| 2021 | 5 | 13 | View |
| 2020 | 5 | 3 | View |
| 2019 | 1 | 14 | View |
| 2018 | 2 | 57 | View |
| 2017 | 1 | 33 | View |
| 2003 | 2 | 9 | View |
| 2002 | 2 | 17 | View |
| 2001 | 4 | 18 | View |
| 2000 | 2 | 36 | View |
| 1999 | 1 | 29 | View |
| 1998 (current) | 1 | 28 | |
| 1997 | 0 | 31 | View |
| 1995 | 2 | 15 | View |
| 1994 | 4 | 12 | View |
| 1993 | 1 | 0 | View |
| 1992 | 1 | 0 | View |
| 1991 | 1 | 0 | View |
| 1990 | 1 | 0 | View |
| 1989 | 1 | 0 | View |