1998 BMW 540i

Defect. 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.

Risk. 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.

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.

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 BROKE.*AK

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 EXPERIENCED DRIVER MAY HAVE DIFFICULTY CONTROLLING VEHICLE TO GET TO SIDE OF ROAD QUICKLY TO SHUT DOWN. NO WAY TO PREDICT THE FAILURE. SAME ISSUE WITH EXPANSION TANK. BOTH FAILURES ARE ON PLASTIC PARTS.*AK

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 THE RADIATOR AND SURE ENOUGH, THERE WAS A LARGE CRACK DOWN THE SIDE OF THE HOUSING. I HAD THE CAR TOWED HOME AND PURCHASED A NEW RADIATOR FROM BMW OF SEATTLE THE FOLLOWING MORNING. THE NEW RADIATOR WAS ABOUT $200, A FEW HOURS OF MY OWN LABOR AND A FEW MORE HOURS DETAILING THE ENGINE PAY AND HEADLIGHTS WHICH HAD RADIATOR FLUID ALL OVER THEM. ALSO FROM THE EXPERIENCE OF OTHERS WHO OWN E39 BMW 540S, I FULLY EXPECT THIS TO HAPPEN AGAIN IN THE NEXT 50K MILES. I ALSO EXPECT THE EXPANSION TANK TO GO WITHIN THE NEXT FEW MONTHS. *AK

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

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 KNOWN TO BE VERY HIGH. HTTP://WWW.VOTATIONS.COM/ASP/SURVEYRESULTS.ASP?POLLID=66461 .*AK

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.

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 FOR BMW 540I, THIS IS WELL DOCUMENTED ON VARIOUS WEB SITES OF BMW OWNERS. BEARINGS LAST 75,000 MILES!

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 PAST. DELER COULDN'T FIX, RESULTING IN SAFETY HAZARD.

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.

TRUNK LATCH FAILED. TRUNK STAYS OPEN. DEALER REPLECED ACTUATOR.

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.

ENGINE IDLES ROUGH AND STALLS WHILE DRIVING. DEALER REPLACED FAULTY CAMSHAFT SENSOR UNDER WARRANTY.

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.

SECOND RADIATOR FAILURE AT 56,254 MILES IN 10/19/2001 CAUSED POOR VISIBILITY. DT

RADIATOR FAILED WITHOUT WARNING. STEAM OBSCURRED VISION. DT

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 ENTERMITTENTLY STALLED WHEN THE CLUTCH IS DEPRESSED WHILE DRIVING AND IS RELATED TO AN INTERMITTENT LOW RMP ENGINE MALFUNCTION. YH

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 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.