1998 BMW 540Ia

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.

THE INSIDE DOOR HANDLES OF MY CAR (1998 BMW MODEL 540IA) ARE CONSTRUCTED OF LOW GRADE / FRAGILE PLASTIC MATERIAL WHICH BREAKS DURING NORMAL USAGE. WITHOUT A HANDLE IT IS VERY DIFFICULT TO EXIT THE VEHICLE. AN EXTREMELY HAZARDOUS SITUATION RESULTS WHEN THIS HANDLE HAS BROKEN BECAUSE IN CASE OF AN ACCIDENT, A DRIVER, OR PASSENGER, WILL BE TRAPPED IN THE VEHICLE. TO ESCAPE, THAT PERSON WOULD HAVE TO CRAWL TO THE OTHER SIDE OF THE CAR OR TO THE FRONT/REAR SEAT TO OPEN A DOOR. IN CASE OF AN INJURY FROM THE ACCIDENT THIS MIGHT NOT BE POSSIBLE. THIS HAZARDOUS SITUATION IS A RESULT OF THE MANUFACTURERS USE OF LOW QUALITY MATERIALS IN SUCH AN IMPORTANT COMPONENT AS THE DOOR HANDLES USED FOR EMERGENCY EXIT. A STRONGER MATERIAL WHICH IS NOT SO EASILY BROKEN SHOULD BE USED FOR THESE PARTS - SUCH AS STEEL.*AK

VARIOUS PROBLEMS INVOLVING 1998 BMW 540IA WHICH WAS BROUGHT USED. *MR BMW HAD BEEN IMPORTING VEHICLES FOR SALE, FITTED WITH A RADIATOR THAT HAD PLASTIC ENDS AS WELL AS SUPPLY AND RETURN UNDER APPROXIMATELY 21 P.S.I. THESE RADIATORS SUDDENLY RUPTURED UNDER LOAD WHILE DRIVING, CAUSING THE DRIVERS TO SWERVE ON IMPULSE AT IMPACT OF THE RUPTURE. THE RADIATOR WAS LIKELY TO RUPTURE AT ABOUT 80K MILES. *SC *JB

RADIATOR FAILURE. *JB