2022 BMW 540I

The Office of Defects Investigation (ODI) received on September 1, 2026 a defect petition dated August 5, 2026, requesting an investigation into an alleged defect in BMW rear differential assemblies. The petitioner alleges Model year (MY) 2022 BMW 540i vehicles are experiencing a sudden mechanical failure that severs the drive connection between the driveshaft and the rear wheels. This defect petition has been opened to evaluate the issue and determine whether to grant or deny the petition. BMW filed Safety Recall 26V525 on August 12, 2026. The petition can be reviewed at NHTSA.gov under ODI number 11761650.

NHTSA received a petition on or about July 18, 2022, requesting that Federal Motor Vehicle Safety Standard (FMVSS) 141 be applied to all electric and hybrid vehicles operating in the United States. The petition can be reviewed at NHTSA.gov under ODI Number 11486072. FMVSS 141 establishes performance requirements for pedestrian alert sounds for motor vehicles. The standard applies to hybrid and electric vehicles that have a gross vehicle weight rating of 4,536 KG or less or are defined as low-speed vehicles. The standard became fully applicable to all such vehicles manufactured on or after March 1, 2021.On January 27, 2023, NHTSA opened Defect Petition (DP) 22-005 to evaluate the subject matter described in the petition. On June 24, 2023 and as supplemented on June 25, 2023, the petitioner notified NHTSA he was withdrawing his petition. The petitioner indicated that, based on his review of data, there is no justification for asserting potential benefits that could be derived from actions sought by my petition. Based on the petitioner's withdrawal, DP22-005 is closed. Closure of this DP does not represent a determination by NHTSA regarding the subject matter of the petition.

See attached Petition letter for complaint.

NHTSA ID

11761650

Incident

Jul 14, 2026

On XXX, while stopped at a traffic light, I accelerated normally in my 2022 BMW 540i. After moving only a few feet, I heard a loud metallic clank from the rear of the vehicle. The vehicle immediately lost all ability to propel itself. It would still shift between gears, but pressing the accelerator would not move the vehicle. A drivetrain warning appeared after the failure. There were no meaningful warning symptoms beforehand. The vehicle was towed to an authorized BMW dealer (Paul Miller BMW in [XXX]), where the rear differential/driveline was identified as the apparent failed component. The vehicle remains completely inoperable and is available for inspection. NHTSA identifies this vehicle as subject to Recall 26V525. The recall concerns excessive wear at the connection between the driveshaft and rear differential and warns that the defect can result in loss of power to the rear wheels and possible vehicle rollaway. The failure I experienced appears consistent with the condition described in that recall. The recall is currently listed as “Recall Incomplete, remedy not yet available.” I contacted BMW North America and the servicing BMW dealer because the vehicle has already experienced the apparent recalled failure and cannot be driven. The dealer advised me that BMW became involved but, because the recall is presently “unclear,” BMW would not provide documentation confirming whether the failed rear differential is covered. I was further advised that the only current option is to pay for the repair and seek reimbursement once the recall remedy becomes available. This leaves me with an immobilized vehicle subject to an active federal safety recall involving the same driveline components that failed, but with no current remedy or definitive coverage determination. My third-party service-contract administrator is also declining to authorize the repair because BMW has announced responsibility for the recall condition. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11761005

Incident

Aug 15, 2026

Rear differential failed, internal gears compromised. Noticed problem when going into gear. Vehicle no longer is able to go in gear and will shut off engine. No indication lights prior to failure. Vehicle showed drivetrain error as soon as it had failed. Vehicle was in main road when failure occurred, placing vehicle at risk. Upon BMW technician inspection, there were no leaks, fluid was clean but internal gears were compromised. BMW dealership in New York is unable to provide a problem cause. The rear differential failure caused driveshaft failure which also required replacing. However, the dealer is unaware as to how this could have happened, especially since this vehicle has been dealer-maintained. With no prior indication of failure and dealer unable to explain reason of failure, I request this to be investigated as there may be other vehicles experiencing the same failure.

NHTSA ID

11760936

Incident

Aug 23, 2026

While turning my 2022 BMW 540i onto a busy, 50 MPH road, the vehicle suffered a catastrophic drivetrain failure, without any physical trauma such as encountering a curb or pothole. The car experienced a total and immediate loss of motive power (propulsion), leaving me coasting in live traffic. This created an extreme safety hazard as I was unable to accelerate or maintain speed to clear the roadway safely. The failure occurred immediately after a significant temperature stress: taken from a heated garage, driven with no issue for 40 minutes, then parked in 15 degree weather for two hours, then complete failure within moments of starting up after the two hour cold parking block. My reading since the incident reveals that BMW quietly switched a critical drivetrain part from a composite/plastic material to metal in later 2022 production runs, due to temperature tress failures precisely as I experienced. This 'silent fix' suggests a known design defect in early 2022 models that poses a recurring risk of sudden propulsion loss. BMW did not do a recall for this, but they should have: I and other drivers were in real danger when my car spontaneously lost all motive ability in high speed traffic.

NHTSA ID

11715820

Incident

Feb 3, 2026

Passenger Restraint service message. Possibly related to airbag seat or floor sensor. Checked BMW customer forums and appears to be widespread issue.

NHTSA ID

11677962

Incident

Aug 2, 2025

On Feb.3, 2023, my wife made a turn into a parking lot. She was driving our 2022 BMW 540. She paused and the engine began to rev up. It then shot forward nearly 50 feet and hurled her over a meridian into another car. She pressed as hard as she could on the brake and suffered a torn meniscus ligament. There were no warning lights and although the car hit front right, no airbags were executed. BMW has not sent an official detailed report from their engineer. BMW advertises brake override so pressing both the brake and accelerator would NOT result in this event.

NHTSA ID

11513257

Incident

Feb 3, 2023

The EVAP systems purge (vent) valve limited warranty for defects in materials or workmanship has been extended to 15 years / 150,000 miles as determined from the original in-service date.

One or more of the LED daytime running lights are dim or discolored.

Check Control message (CCM) indicates: (ID 213): Stop, exercising due care. Voltage supply The Service Engine Soon light is on with the following DME Fault Code: 21B209 - Starter alternator / belt for 48V system (OSA_RIEMEN_RISS): Belt betweenCombustion engine and starter generator torn And/or one or more of the following other issues are also occurring: Noise in the area of the belt drive. Odor from the engine compartment. Smoke formation in the area of the belt drive. Drive belt damaged or prematurely worn. Torn drive belt.

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.

At low outside temperatures (below 40 degrees F) and slow driving speeds (i.e. when parking, maneuvering)with a large steering angle, the front end can be slightly axially misaligned. This can be felt (jerking)/ heard via an acoustic acknowledgement (clunk) as seen at the 11 second mark of the video. See attached video V36 01 21.