2015 BMW 435I

From 2000 through 2017, Takata produced millions of air bag inflators using two types of phase-stabilized ammonium nitrate ("PSAN") propellant -- propellant 2004 and propellant 2004L. After prolonged exposure to high temperature cycles and humidity, inflators using propellant 2004 can degrade, causing the propellant to burn too quickly when ignited. The rapid burning can cause the inflator to rupture during deployment, potentially causing serious or even fatal injury to vehicle occupants. See 2016 Blomquist Report at www.nhtsa.gov/sites/nhtsa.gov/files/documents/expert_report-hrblomquist.pdf.Consequently, all frontal inflators using propellant 2004 that do not contain a "desiccant" (a substance that traps and holds moisture) in US vehicles are under recall. These "non-desiccated" inflators either have been or are required to be replaced.In some cases, the remedy part for these recalled inflators was, or will be, an inflator using either propellant 2004 or 2004L that does contain a desiccant. None of these "desiccated" remedy parts (which were installed in older model year vehicles) are currently under recall for a degradation concern. Certain subsets of desiccated PSAN inflators using propellant 2004 for use as original equipment, however, have been recalled for a degradation concern. All Takata inflators produced with propellant 2004L contain desiccant, and none of these desiccated inflators using propellant 2004L are under recall for a degradation concern. There have been no reported field ruptures in any non-recalled desiccated PSAN inflators.It is understood that desiccants fully saturate at some threshold, at which point any additional moisture will not be captured. This means the degradation process observed in non-desiccated inflators using propellant 2004 may also occur in non-recalled desiccated inflators using propellant 2004, assuming additional moisture enters the inflator and high temperature cycling occurs. Based on available information, desiccant saturation can occur within the first five years in the worst environments, and the time required for full saturation is affected by multiple factors. While no present safety risk has been identified, further work is needed to evaluate the future risk of non-recalled desiccated inflators using propellant 2004.Three entities -- Takata (now known as TK Global), the Independent Testing Coalition, and Exponent -- have been studying the long-term behavior of Takata desiccated PSAN inflators using propellant 2004L (as well as 2004) in the presence of moisture and temperature cycling. The research efforts, which include development of predictive modeling techniques and field sample analysis, are ongoing. To date, none of the researchers have identified field evidence showing that propellant 2004L is undergoing a degradation process that leads to aggressive deployment and potential rupture. However, the time in service of such inflators remains short compared to that of the inflators using propellant 2004. Further study is needed to assess the long-term safety of desiccated inflators using propellant 2004L.The Office of Defects Investigation is opening this investigation to examine whether a safety defect related to propellant degradation exists in non-recalled desiccated PSAN frontal inflators manufactured by Takata. This investigation will require extensive information on Takata production processes and surveys of inflators in the field. Lists of recall actions that may have used desiccated PSAN inflators as remedy parts, as well as the makes and models originally manufactured with them, is available with the downloadable version of this document (see nhtsa.gov/recalls?nhtsaId=EA21002 -- note this information is subject to change/revision as the investigation proceeds). This investigation does not supersede EA15-001, which remains open.

I am submitting this complaint regarding a 2015 BMW 435xi (N55 engine, ~79,000 miles) that suffered a sudden and complete engine failure due to the oil pump drive chain. While driving at highway speed, the vehicle experienced an instant loss of oil pressure and engine seizure without any warning lights or prior symptoms. I barely managed to steer the car to the shoulder and avoid being struck by surrounding traffic. This was a serious safety hazard, as the loss of power and steering control occurred in active highway conditions. Inspection revealed a catastrophic internal failure of the oil pump drive chain. This is not related to neglect, lack of maintenance, or external damage—the vehicle had received an oil service at a BMW dealership only two months prior. Importantly, the N55 engine uses the same oil pump chain and guide architecture as BMW’s N20/N26 4-cylinder engines. BMW has already acknowledged premature failures of this system in those engines and provided extended warranty coverage. The fact that this defect is now occurring in the N55 platform demonstrates a broader systemic issue. This failure at relatively low mileage creates a significant safety risk to drivers and passengers, as well as other vehicles on the road. A sudden seizure of the engine at highway speed leaves little to no opportunity to maneuver safely and avoid collisions. I urge the agency to investigate this issue as a potential design defect affecting the N55 engine family. BMW should be required to provide recall or warranty remedies similar to those extended for the N20/N26 engines. Thank you for your attention to this serious safety matter.

NHTSA ID

11685069

Incident

Aug 23, 2025

I own a 2015 BMW 435i from Checkered Flag (Jaguar) in about 2017. The car is currently experiencing a fuel pump failure of exactly the type that is described here: [XXX] . Your VIN lookup does not show my car is covered by the recall, even though my car is exactly the make and model described in the recall notice. Moreover, the defect my car is experiencing is exactly the defect described in the recall notice. It makes little sense that some cars of this make and model would have a fuel pump problem but not others; it is far more likely the fuel pumps are common to all cares of this make and model and somehow my VIN was left off the recall list. I’d like to ask you to look further into it, as it appears to be quite a coincidence that my fuel pump failed in the manner described in the recall notice. My servicing dealership is Checkered Flag BMW in Virginia Beach VA INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11614039

Incident

Sep 8, 2024

DOORS LOCKS HAVE A DOUBLE PULL FEATURE WHERE THE FIRST PULL WILL UNLOCK THE DOOR AND THE SECOND PULL WILL ALLOW THE DOOR TO OPEN. THE FIRST PULL WILL OCCASIONALLY FAIL TO UNLOCK THE DOOR LOCK MECHANISM. THE FAILURE PERMANENTLY PREVENTS THE DOOR FROM OPENING UNLESS THE OPERATOR PRESSES THE DOOR LOCK/UNLOCK BUTTON, LOCATED ON THE CENTER DASH, MULTIPLE TIMES.

NHTSA ID

11311529

Incident

Feb 24, 2019

Mileage

56,700 mi

INTERMITTENTLY UNABLE TO OPEN THE DRIVER SIDE DOOR WHEN PULLING THE INTERIOR DOOR HANDLE WHEN THE DOOR IS LOCKED, DUE TO THE BOWDEN CABLE BECOMING TWISTED YOU ARE UNABLE TO OPEN THE DOOR WITHOUT USING THE CENTER UNLOCK BUTTON. IN THE EVENT OF A FIRE OR THE BATTERY BEING DEAD YOU'D HAVE TO USE THE PASSENGER DOOR. THERE WAS A TSA FROM BMW ON THIS ISSUE FOR A LIMITED SET OF VEHICLE, SEE BELOW, THAT I FEEL NEED TO BE EXPANDED TO A RECALL REGARDING THE POTENTIAL SAFETY ISSUE SINCE IN RESEARCHING THIS ISSUE IT APPEARS TO EFFECT MORE VEHICLES THEN ARE LISTED IN THE TSB. TSB 51 26 15, DATED SEP 1, 2015 DESCRIBES THE PROBLEM WHEN THE BOWDEN CABLE MALFUNCTIONS IN COLD WEATHER. REROUTING OF THE CABLE IS RECOMMENDED. PLEASE FEEL FREE TO CONTACT ME TO DISCUSS THIS IN MORE DETAIL, [XXX]. THANKS, [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ID

11302967

Incident

Jan 8, 2020

Mileage

43,000 mi

DOORS WILL NOT UNLOCK FROM THE INSIDE WHEN PULLING THE HANDLE. REGARDLESS OF WHETHER VEHICLE IS ON OR OFF.

NHTSA ID

11277684

Incident

Nov 1, 2019

THE FRONT STRUT MOVES DOWN THE SPINDLE HITTING THE FRONT DRIVE SHAFT NO LOOSE BOLT FOUND DEFECTIVE DESIGN THE BOLT SECURE IT TO THE SPINDLE TOO SMALL AND NO NOTCH ON THE STRUT OR BRACKET ON STRUT TO SECURE THEM FROM COMING APART VERY DANGEROUS LOOSE VEHICLE CONTROL I'M A CERTIFIED ASE MASTER TECHNICIAN

NHTSA ID

11162840

Incident

Nov 23, 2018

Mileage

41,000 mi

WHEN THE VEHICLE IS STATIONARY, AND THE ENGINE IS NOT OPERATING, THE "DOUBLE-PULL" OPERATION TO UNLOCK THE DOOR MALFUNCTIONS INTERMITTENTLY AND WITHOUT WARNING OR NOTICE. THIS IS A RECURRING PROBLEM WITH MANY VEHICLES ACROSS MULTIPLE PRODUCT OFFERINGS (BOTH SERIES AND YEAR) WITHIN THE BRAND.

NHTSA ID

11154394

Incident

Nov 28, 2018

Mileage

20 mi

MY CAR HAS LESS THAN 19,000 MILES AND BOTH FRONT TIRES HAVE GOLF BALL SIZE BLOW OUTS IN THE SIDE WALLS ON THE FRONT TIRES. ALMOST IN THE SAME SPOT ON THE TIRES. THE REAR TIRE ARE FINE

NHTSA ID

11145053

Incident

Oct 22, 2018

Mileage

18,600 mi

The basic conditions for initializing the power windows are not met.

The electrical system of BMW vehicles has been subject to an ongoing development process over the last few years. This has led to increased demands being placed on the battery. This document covers important information for the dealer on how to handle “discharged battery” complaints.

The paint finish on the door jamb (above the door striker) is scratched due to the inner door cavity window seal.

?The front seat will not calibrate/initialize, and the stored faults cannot be deleted.

After programming the head unit (HU-H2), activating the FSC (German word Freischaltcode) Enabling Codes repeatedly fails.

Upon opening and closing the tailgate, a creaking/groaning sound can be heard from tailgate actuator.