2018 BMW X5

The Office of Defects Investigation (ODI) opened PE21-021 on October 14, 2021, to investigate incidents alleging a stall/loss of motive power as a result of high-pressure fuel pump failures in certain model year (MY) 2019-2020 Ram 2500, 3500, 4500, and 5500 heavy duty trucks equipped with 6.7L Cummins turbodiesel engines. During the investigation, ODI sought to determine if the related defect allegation was limited in scope to the recalled population. After review of information request response materials from both FCA and BMW, NHTSA determined that sufficient information to identify a comprehensive recall population could not be produced by FCA and BMW.During the investigation FCA filed recalls 22V406, 22E048, 22V767, and 22E087 which include vehicles not identified in the initial subject population by ODI. ODI also received recall 21V586, involving loss of motive power due to failed CP4 fuel pumps on certain BMW manufactured vehicles. An information request letter response received from BMW indicated that failed pumps on their vehicles were caused by an interaction between pump internal components and US market diesel fuel, leading to increased slip and eventual particle-generating wear surface. Additional work will be done to identify whether a similar root cause is associated with the FCA recalled population and if similar wear dynamics occur on pumps supplied to vehicle manufacturers other than those included in the recalled population.ODI has upgraded this investigation to an EA in order to 1) determine engineering specifications of internal pump components that are correlated with pump failure leading to loss of motive power or other safety related hazards, 2) identify vehicle populations equipped with alleged defective pump variants, 3) assess if vehicles equipped with alleged defective pump variants result in an unreasonable risk to motor vehicle safety and 4) gather and review any other relevant information related to high pressure fuel pump failure associated with the subject populations of recalls 21V586, 21V880, 21E094, 22V406, 22E048, 22V767, and 22E087.Review of the above information will allow NHTSA to confirm root cause and recall remedy viability, and identify and evaluate vehicle populations equipped with pump components that may pose an unreasonable risk to motor vehicle safety.The ODI reports cited above can be reviewed at: http://www-odi.nhtsa.dot.gov/owners/SearchNHTSAID using the following complaint identification numbers: 11257550, 11351441, 11361603, 11361616, 11365300, 11365426, 11365858, 11366401, 11372337, 11373793, 11374797, 11376793, 11377871, 11378173, 11384377, 11386063, 11387018, 11399710, 11402550, 11415339, 11418868, 11418870, 11427075, 11434276, 11436807, 11437226, 11437249, 11437273, 11437292, 11437294, 11437394, 11437399, 11437403, 11437405, 11437423, 11437528, 11437565, 11437579, 11437580, 11437590, 11437679, 11437744, 11437781, 11437842, 11437993, 11438006, 11438008, 11438121, 11438138, 11438155, 11438392, 11438629, 11439359, 11439879, 11440397, 11443030, 11446542, 11448163, 11453556, 11458918, 11460558, 11469337

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.

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.

I am reporting a recurring catastrophic high-pressure fuel-pump/fuel-system failure in my 2018 BMW X5 after BMW previously repaired the same type of failure, and subsequently performed the NHTSA HPFP recall on my vehicle. I am a 71 year old driver. This was a repeat catastrophic failure after Recall 21V-586 was performed and the loss of propulsion on the freeway was terrifying, and I almost crashed into other cars! At 42,763 miles, the vehicle experienced a catastrophic failure while being driven. The vehicle shut off while driving and would not restart. Santa Monica BMW documented a “HIGH PRESSURE FUEL PUMP MALFUNCTION” and fault codes. BMW's technician followed the fuel-system test plan and reported that the fuel quality control valve had metal shavings. See Invoice 42,763.pdf BMW subsequently issued NHTSA Recall 21V-586 concerning the HPFP on affected BMW diesel vehicles, including my vehicle. BMW performed the recall repair at Weatherford BMW at approximately 58,292 miles. The repair order identifies the work as “PERFORM RECALL B130121 HIGH PRESSURE FUEL PUMP” and documents replacement of the high-pressure fuel pump. See Invoice 58,292. At 120,945 miles, the vehicle experienced another, similar catastrophic failure while I was again driving on a freeway. Weatherford BMW subsequently diagnosed multiple fuel/rail-pressure faults. The technician removed the fuel quantity control valve to check for swarf and found magnetic metal shavings in the fuel system. See Invoice 120,945 These failures are particularly concerning to my safety. I am submitting this complaint to the NHTSA because I believe the recurrence of a catastrophic system failure, including metal contamination and loss of propulsion, after BMW previously replaced the complete fuel system under warranty and subsequently performed the HPFP recall remedy, warrants investigation to determine whether the recall remedy or the underlying HPFP/fuel-system defect can cause a subsequent failure of this nature.

NHTSA ID

11756344

Incident

Jul 28, 2026

The attaching nut and bolt holding the left suspension to the rear subframe worked itself lose. The nut had completely fallen off. The corresponding bolt was merely hanging on but was about to fall off too. The vehicle was behaving weirdly and unstable even at slower speeds.

NHTSA ID

11739474

Incident

May 21, 2026

On March 9, 2026, I brought the vehicle to BMW of Fairfax for a scheduled appointment. In the week leading up to the visit, the vehicle intermittently failed to start and required jump-starting using a portable battery starter. Despite this issue, the car drove normally, showed no warning lights or error messages, and had approximately 69,000 miles on the odometer at the time. After jump-starting the vehicle, I personally drove it to the dealership. I paid for a diagnostic evaluation and also authorized completion of a minor recall. Two days later, I was informed that the vehicle was no longer able to shift into gear and was now completely inoperable. I was told I would be responsible for towing the vehicle off their premises. According to the service department, the vehicle now requires replacement of the EME module, at an estimated cost of $12,000. This assessment was particularly troubling because the vehicle was fully drivable when it arrived at the dealership. At no point prior to service did the car have difficulty shifting into gear. It is deeply concerning that the vehicle became a “brick” while under the care of an authorized BMW service center, with no accountability taken for what occurred during their diagnostic process.

NHTSA ID

11734949

Incident

Mar 9, 2026

EGR system coolant leak and white smoke from exhaust

NHTSA ID

11732848

Incident

Apr 21, 2026

I experienced a complete failure of the rear pneumatic (air) suspension system on my vehicle. This system uses rubber air springs (“airbags”) rather than conventional coil springs. When it failed, the rear of the vehicle dropped significantly, causing metal-to-metal contact, an extreme upward pitch of the front end, and pronounced instability. The vehicle became difficult to control, with excessive rear sway creating an unsafe driving condition. Based on my experience and publicly available information, this appears to be a known and recurring issue affecting BMW X5 and X6 models (E70, F15, and G05). The failure is commonly attributed to degradation of the rubber air springs, which can dry out, crack, or leak. When leaks develop, the compressor runs excessively and may fail, resulting in sudden loss of suspension support. While these components may be considered wear items, the frequency and relatively early occurrence of these failures suggest a design or engineering vulnerability rather than typical maintenance. Failures are widely reported between approximately 50,000 and 100,000 miles or within 4–7 years, indicating a pattern of premature degradation. This condition can occur without clear warning, including after the vehicle has been parked, meaning drivers may not recognize the issue until the vehicle is unsafe to operate. Once the system fails, handling is severely compromised, increasing the risk of loss of control. Repair costs often exceed $5,000, which may discourage timely repairs and leave vehicles in unsafe condition. BMW characterized this as a maintenance issue despite the apparent pattern. I am submitting this complaint because this condition poses a serious safety risk. A sudden loss of rear suspension support at speed could result in loss of control, increasing the risk of a crash, injury, or fatality.

NHTSA ID

11731591

Incident

Apr 8, 2026

Vehicle: 2018 BMW X5 xDrive40e Recall: NHTSA Safety Recall 24V-608 Complaint Description: My 2018 BMW X5 xDrive40e experienced a sudden Electric Motor Electronics (EME) failure that rendered the vehicle inoperable. This occurred before the recall remedy for NHTSA Safety Recall 24V-608 was completed. It is available for inspection upon request. Recall 24V-608 addresses fluid intrusion into the electric coolant water pump electrical connector, which can cause electrical shorts, overcurrent conditions, and power instability. The EME is directly dependent on stable electrical conditions. After the vehicle failed, the recall repair was performed; however, completion of the recall does not reverse electrical damage that may have occurred prior to the repair. Prior to the EME failure, I made multiple attempts to have the recall addressed by contact BMW authorized dealers, but the recall condition remained unresolved. Following the failure, BMW of North America denied responsibility in writing, closed my case, and did not identify any alternative root cause or provide technical findings explaining the EME failure. The vehicle is not drivable and requires approximately $12,000 in repairs. I also incurred rental vehicle expenses as a result of BMW’s refusal to repair. This appears to be recall-related electrical damage affecting a critical control module, creating a safety concern due to sudden loss of vehicle function putting safety of myself and others at risk. I am submitting this complaint to document a safety-related electrical failure associated with Recall 24V-608 and BMW of North America’s refusal to remedy the resulting damage.

NHTSA ID

11718491

Incident

Oct 1, 2025

I replaced an Electric Auxillary Heater on my vehicle in 2024 part that was subsequently offered an warranty extension on 8/1/2025 by BMW in Service bulletin SIB 01 10 25. The bulletin had a provision for customer reimbursement of repairs and they are refusing to honor my claim. I think they should be forced to place this part into a recall by NHTSA. These vehicles are lemons. A High Voltage AC compressor, Electric Auxillary Heater Issues, High Voltage power supply cables, Turbocharger, Electric Suspension compressor, Air suspesion Springs, Evaporative Emissions Purge Valve all had to be replaced before the vehicle hit 90,000 miles.

NHTSA ID

11693892

Incident

Apr 25, 2024

Driving the vehicle a short distance, I can smell oil burning after the car is stopped. I have had to put oil in the car twice because the warning light came on suggesting that a quart of oil is needed. The vehicle has less than 122,000 miles. Also, the car idles a lot before I put it in gear. I was told at the last oil change that I need spark plugs. The battery and tires were replaced by a BMW dealership over a year ago.

NHTSA ID

11690659

Incident

Sep 30, 2024

N63TU1 CLASS ACTION SETTLEMENT SVC CAMPAIGN: OIL CONSUMPTION DIAGNOSIS/REPAIR

The Exhaust Gas Recirculation (EGR) Cooler (with EGR Valve) and the Auxiliary Exhaust Gas Recirculation (EGR) Cooler limited warranty for defects in materials and / or workmanship has been extended to 25 years without mileage limit as determined from the original first in-service / delivery date.

The electric auxiliary heater assembly limited warranty for defects in materials and / or workmanship has been extended to 10 years / 120,000 miles as determined from the original first in-service / delivery date

SCR Container Return

The High-Voltage (HV) Battery Assemblys Cell Modules Temperature Sensors (Internal NTC repair kit-specific) limited warranty for defects in materials or workmanship has been extended to 10 years / 120,000 miles as determined from the original in-service/first delivery date

The High-Voltage (HV) Battery AssemblysCell Modules Temperature Sensors (Internal NTC repair kit-specific) limited warranty fordefects in materials or workmanship has been extended to 10 years / 120,000 miles asdetermined from the original in-service/first delivery date.