2004 BMW M3

The Office of Defects Investigation (ODI) opened PE14-016 in June 2014 based on six inflator rupture incidents involving consumer owned vehicles produced by five vehicle manufacturers.All six vehicles were operated in Florida or Puerto Rico at the time of the rupture and for the majority of their service life, and were equipped with inflators produced by Takata, a tier-one supplier of automotive air bag systems.During the course of PE14-016, ODI determined that five additional vehicle manufacturers used inflators of a similar design and vintage also supplied by Takata. No evidence of field failures was found in vehicles produced by these five additional manufacturers.Nonetheless, at ODI's insistence, all 10 vehicle manufacturers initiated a regional recall within approximately two weeks of the opening of the investigation.The regions recalled initially included Florida, Puerto Rico, Hawaii, and the U.S. Virgin Islands, areas with high absolute humidity and climatic conditions believed to be a significant factor in the inflator ruptures.As part of the recall actions, inflators removed from remedied vehicles are to be returned to Takata for testing.Takata's initial test results on passenger inflators from remedied vehicles indicated a much higher than anticipated rupture frequency for inflators returned from Florida.Accordingly ODI requested all 10 manufacturers expand the regional recalls for passenger inflators to include other geographic areas where high absolute humidity conditions exist, including the Gulf States and other coastal areas.Takata's testing of the passenger inflators to date continues to indicate this geographic area as having the highest risk, with no ruptures occurring from inflators returned from outside the expanded recall regions.During PE14-016 four additional passenger inflator field events occurred, all in vehicles from the same expanded geographic region.Also during PE14-016 four additional driver inflator field events occurred including two in vehicles from regions not known for high absolute humidity, specifically California and North Carolina.Accordingly, ODI requested all five of the affected vehicle manufacturers currently using the subject Takata driver inflators expand to nationwide recalls.Significantly, neither of the affected vehicle manufacturers or Takata provided any explanation to account for these two driver air bag inflator ruptures outside the area of high absolute humidity.Takata testing of returned driver inflators indicates a lower rupture frequency as compared to passenger inflator testing.All test ruptures reported by Takata to date have occurred on inflators returned from high absolute humidity areas.The investigation now includes all manufacturers and vehicles known to be affected at this time.ODI's investigation will focus on, among other things, root cause analysis, other potential defect consequences, identification of affected vehicles scope, and adequacy of the remedy.The five ODI reports cited above can be reviewed online at http://www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification numbers: 10537899, 10568848, 10585224, 10605877, 10651492

The Office of Defects Investigation (ODI) opened PE14-016 in June 2014 based on six inflator rupture incidents involving consumer owned vehicles produced by five vehicle manufacturers.All six vehicles were operated in Florida or Puerto Rico at the time of the rupture and for the majority of their service life, and were equipped with inflators produced by Takata, a tier-one supplier of automotive air bag systems.During the course of PE14-016, ODI determined that five additional vehicle manufacturers used inflators of a similar design and vintage also supplied by Takata. No evidence of field failures was found in vehicles produced by these five additional manufacturers.Nonetheless, at ODI's insistence, all 10 vehicle manufacturers initiated a regional recall within approximately two weeks of the opening of the investigation.The regions recalled initially included Florida, Puerto Rico, Hawaii, and the U.S. Virgin Islands, areas with consistently high absolute humidity and climatic conditions believed to be a significant factor in the inflator ruptures.As part of the recall actions, inflators removed from remedied vehicles are to be returned to Takata for testing.Takata's initial test results on passenger inflators from remedied vehicles indicated a much higher than anticipated rupture frequency for inflators returned from Florida.Accordingly, ODI requested all 10 manufacturers expand the regional recalls for passenger inflators to include other geographic areas where high absolute humidity conditions exist, including the Gulf States and other coastal areas.Takata's testing of the passenger inflators to date continues to indicate this geographic area as having the highest risk, with no ruptures occurring from inflators returned from outside the expanded recall regions.During PE14-016, four additional passenger inflator field events occurred, all in vehicles from the same expanded geographic region.Also during PE14-016, four additional driver inflator field events occurred including two in vehicles from regions not known for high absolute humidity, specifically California and North Carolina.Accordingly, ODI requested all five of the affected vehicle manufacturers currently using the subject Takata driver inflators expand to nationwide recalls.Significantly, neither of the affected vehicle manufacturers or Takata provided any explanation to account for these two driver air bag inflator ruptures outside the area of high absolute humidity.Takata testing of returned driver inflators indicates a lower rupture frequency as compared to passenger inflator testing.All test ruptures reported by Takata to date have occurred on inflators returned from high absolute humidity areas.The PE is now closed/upgraded to an Engineering Evaluation (EA15-001) to include all manufacturersand vehicles known to be affected at this time.ODI's EA investigation will focus on, among other things, root cause analysis, other potential defect consequences, identification of affected vehicles scope, and adequacy of the remedy.The recalls related to this PE are: 14V343, 14V344, 14V348, 14V351, 14V353, 14V655, 14V700, 14V701, 14V752, 14V763, 14V770, 14V773, 14V787, 14V802 and 14V817.The number of vehicles affected are an estimate since some vehicles may have both the driver and passenger side inflators recalled. The five ODI reports cited above can be reviewed online at http://www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification numbers: 10537899, 10568848, 10585224, 10605877, 10651492

ODI HAS RECEIVED COMPLAINTS FROM CONSUMERS STATING THAT THEIR TAIL LIGHT ASSEMBLY IS NOT PROPERLY ILLUMINATING.THE TAIL LIGHT ASSEMBLY CONSISTS OF A TURN SIGNAL LAMP, A TAIL LAMP AND A BRAKE LAMP.THE COMPLAINANTS HAVE INDICATED THAT THE ISSUE IS WITH AN 8 PIN CONNECTOR AND ASSOCIATED GROUND WIRING.THESE COMPONENTS ARE ALLEGEDLY OVERHEATING AND MELTING DUE TO EXCESSIVE ELECTRICAL CURRENT THAT RUNS THROUGH THE SYSTEM.BMW ISSUED A TECHNICAL SERVICE BULLETIN (TSB) SIB-630306 ON FEBRUARY 2007 TO ADDRESS THE CONDITION BY ADDING SUPPLEMENTARY GROUND WIRING TO THE TAIL LAMP ASSEMBLY.ODI IS UPGRADING TO AN EA TO FURTHER INVESTIGATE THE ISSUE.

IN MARCH 2009, THE OFFICE OF DEFECTS INVESTIGATION (ODI) RECEIVED A PETITION FROM MR. MARK PETERS REQUESTING AN INVESTIGATION OF REAR LAMP FAILURE IN MODEL YEAR 2002-2005 BMW 3-SERIES VEHICLES.AN INFORMATION REQUEST LETTER WAS SENT TO BMW IN APRIL 2009, AND ODI RECEIVED BMW'S RESPONSE IN JUNE 2009.THE TAIL LAMP ASSEMBLY CONTAINS LIGHTING FOR THE BRAKE LAMPS, TAIL LAMPS, AND TURN SIGNALS.A TECHNICAL SERVICE BULLETIN (TSB) WAS ISSUED BY BMW IN JANUARY OF 2007 INSTRUCTING SERVICE TECHNICIANS TO EXAMINE AN 8 PIN ELECTRICAL CONNECTOR FOR HEAT-RELATED DAMAGE AND TO INCORPORATE ADDITIONAL GROUND WIRING TO THE CONNECTOR.COMPLAINANTS HAVE ALLEGED THAT SIGNIFICANT THERMAL DAMAGE TO THE CONNECTOR AND ASSOCIATED GROUND WIRING HAS OCCURRED.THIS CONDITION CAN RESULT IN INTERMITTENT OR TOTAL LOSS OF ALL LIGHTING (BRAKE, TAIL, AND TURN SIGNAL) FOR THE EFFECTED REAR LAMP ASSEMBLY.ODI WILL OPEN A PRELIMINARY EVALUATION TO FURTHER EXAMINE THIS ISSUE INCLUDING FURTHER EVALUATING BMW COMPLAINTS AND RELATED WARRANTY DATA.

Below is a partial email to a BMW Dealer that replaced an airbag 2 1/2 years ago per a recall. The airbag light, convertible top light were both illuminated when I left the dealer. I have sent emails and contacted BMW USA. A friend scanned the car with a Snap-On scanner that showed that the light has been illuminated because of the air bag that they replaced. They continue to avoid the issue and they made my car unsafe and allowed me to leave with it. What can be done to resolve this issue? From: [XXX] <[XXX]> Sent: Friday, May 10, 2024 10:06 AM To: '[XXX]' <[XXX]> Subject: Issues with service during an airbag replacement Good morning [XXX], I took my 2004 M3 to BMW of Fort Lauderdale in November 2023 for a passenger-airbag replacement. The airbag light on the dash was illuminated when I received the car. I notified the service manager who stated that the light was not on when he initially got in the car after my arrival. The car was returned to the garage to determine the issue. The car was returned 30 – 45 minutes later and the airbag light continued to illuminate. The service manage told me that the driver’s side airbag which was replaced at a different dealership was causing the issue. I got in the car and notice that an oil pressure and voltage gauge that I installed after rebuilding the engine were not working. Therefore, I notified the service manager of the issue. He asked another manager to talk to me. I asked how they replaced the airbag so I would know where to start troubleshooting the cause. He told me that they were NOT in the fuse box because they removed the airbag from the top of the dash. The airbag light has been constantly illuminated since the airbag was replaced at BMW of Fort Lauderdale. I attached an image that shows two passenger side airbag errors that were displayed on a Snap-on scanner on May 8, 2024. This was caused by work done at BMW of Fort Lauderdale. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11745653

Incident

Nov 14, 2024

Passenger side rear sub-frame crack observed . Vehicle has never been in any accident or collision. It's a commonly know problem about BMW 3 series made between 1999 to 2006 that happens naturally without cause due to manufacture issue, so I decided to look under my car to look for any cracks as described. I identified at least one crack. After calling BMW USA for assitance, I was instructed to bring the car to have it inspected and confirmed by the BMW dealership in Ontario, CA. Dispite me telling them the location of the crack, they concluded there is no crack and nothing needed to be done. Not satified with their inspection, I went to get a second opinion from an independent machanic/ body shop and they confirmed that there is indeed a crack and took clear pictures to show that. If left untreated, these subframe cracks will spread and the rear of the car can fall off along with the rear axel and rear wheels leading to accidents. The cost of fixing such manufacture issure is also costly, $2500 to over $10000 from the estimates I collected.

NHTSA ID

11457998

Incident

Mar 22, 2022

WIRING PROBLEM WITH FACTORY HEADLIGHTS. THIS ISSUE CAUSES HEADLIGHTS TO FLICKER AND EVENTUALLY TURN OFF. IT HAPPENS WHILE THE VEHICLE IS IN MOTION AND SITTING STILL.

NHTSA ID

11197351

Incident

Apr 12, 2017

Mileage

100,000 mi

TL* THE CONTACT OWNS A 2004 BMW M3. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 15V318000 (AIR BAGS); HOWEVER, THE PART TO DO THE REPAIR WAS UNAVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. THE MANUFACTURER WAS MADE AWARE OF THE ISSUE. THE CONTACT HAD NOT EXPERIENCED A FAILURE. PARTS DISTRIBUTION DISCONNECT.

NHTSA ID

10904927

Incident

May 27, 2016

TAKATA RECALL -- IT'S BEEN 2 YEARS SINCE THE RECALL WAS ISSUED, BUT THE MANUFACTURER / DEALERSHIP DO NOT SEEM TO BE ABLE TO GET THE PARTS TO REPAIR MY CAR. THIS ESSENTIALLY RENDERS MY CAR UNSAFE, AND IN MANY WAYS, UNUSABLE. I STILL HAVE NOT HEARD ABOUT A DATE BY WHEN THE PARTS WILL BE AVAILABLE / REPAIR WILL BE DONE.

NHTSA ID

10899259

Incident

Jul 15, 2014

TAKADA RECALL: NOTIFIED BY BMW JULY 2015 DRIVER-SIDE AIR BAG MODULE DEFECTIVE. IN MAY 2016, BMW ADVISED THEY DID NOT KNOW WHEN AIR BAG WOULD BEFIXED. SINCE THEN ANOTHER PERSON HAS DIED. CONCERNED ABOUT SAFETY AND LENGTH OF TIME WAITING FOR FIX.

NHTSA ID

10864851

Incident

Jul 1, 2015

Mileage

91,000 mi

TL* TAKATA RECALL. THE CONTACT OWNS A 2004 BMW M3. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 15V318000 (AIR BAGS); HOWEVER, THE PART TO DO THE REPAIR WAS UNAVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. THE MANUFACTURER WAS NOT NOTIFIED OF THE ISSUE. THE CONTACT HAD NOT EXPERIENCED A FAILURE. VIN TOOL CONFIRMS PARTS NOT AVAILABLE.

NHTSA ID

10845549

Incident

Jul 11, 2015

TL* TAKATA RECALL. THE CONTACT OWNS A 2004 BMW M3. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 15V318000 (AIR BAGS); HOWEVER, THE PART NEEDED TO PERFORM THE REPAIR WAS UNAVAILABLE. THE CONTACT WAS PLACED ON A WAITING LIST. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT TIME FOR THE RECALL REPAIR. THE MANUFACTURER WAS NOT NOTIFIED OF THE ISSUE. THE VIN WAS UNAVAILALBE. THE CONTACT HAD NOT EXPERIENCED A FAILURE. PARTS DISTRIBUTION DISCONNECT.

NHTSA ID

10840347

Incident

Jul 30, 2015

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.

Functional noises (squealing/honking) when braking shortly before the vehicle comes to a stop. CAUSE Material-

Vehicle cannot be opened or closed using comfort access, engine start is not possible, and the vehicle may not start when placing the key against the steering column.

Diagnosis of Compound Brake System Complaints in M Vehicles: 1. Visible cracks are caused by high thermal stresses during rapid heating and cooling of the brake discs. Braking from high speed with cold brake components (less than 212 degrees F) increases the likelihood of cracks to form.

SERVICE ACTION - HEAD AIR BAG HOLDER RETROFIT: A rattle noise may develop from the head air bag (ITS) gas generator contacting adjacent component. This noise can be heard while driving on an uneven roadway.

Discharged Battery Energy Diagnosis Must Be Performed: 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. In order to properly repair the vehicle the first time in the workshop, it is very important that the diagnostic test plans are performed to completion, with all results taken into consideration. Without performing the energy diagnosis test plan, the root cause of the discharged battery cannot be identified. This increases the chances of a repeat repair.