BMW 540I Recalls

The BMW 540i has 4 recalls spanning 1998 through 2018, with the most serious affecting 2000-2003 models where a sports steering wheel replacement involves a Takata-style driver airbag inflator that can rupture and send metal fragments into the cabin, causing serious injury or death. The other airbag concern sits at the opposite end of the production run: on 2017-2018 models, moisture exposure can impair the head airbag inflators, meaning the airbags may not deploy correctly in a crash or the igniter can separate from the inflator housing. The 1999 model year has an electrical issue where the main positive cable running between the generator and starter has thinner-than-specified insulation that can be worn through by its own mounting clip, exposing bare wire and creating a short circuit risk. Going back to the earliest production, 1998 models have a differential pinion shaft that can wear prematurely, first producing noise from the rear differential and eventually causing the shaft to fail and the vehicle to lose drive power.