2019-2025 BMW Cracking Sound from Rear Wheel Arch Panel

Symptoms

Owners of affected 2019-2025 BMW models may experience a distinct "cracking" sound emanating from the rear wheel arch area. This noise is typically heard while driving on both smooth and uneven roads, and it can occur on either the right or left side of the vehicle. If you hear a 2024 BMW 430i cracking sound, this bulletin may apply to your vehicle.

Cause

BMW has determined that the wheel arch support panel might slightly overlap the side frame connection in certain situations. This overlap, combined with tensile and compressive loads experienced during driving, can lead to movement between these panels, which generates the "cracking" sound.

Repair Procedure Summary

To correct the 2024 BMW 430i cracking sound, technicians will rework the rear upper section of the left and/or right-side wheel arch panel. The procedure involves several steps:

1. Panel Removal: The left and/or right wheel and wheel arch trim panel, luggage compartment floor covering, and trunk wheel arch trim panel must be removed. Specific repair instructions for these steps are found in ISTA/AIR documents 51 71 041, 51 47 101, and 51 47 151.
2. Insulating Pad Removal: The insulating pad in the affected area is removed.
3. Drilling: An elongated hole, approximately 15 mm in length, is drilled into the left and/or right wheel arch panel. Technicians must maintain a distance of 4 mm from existing spot welds. The wheel arch panel thickness is 1mm.
4. Welding: The newly drilled elongated hole is welded, ensuring the two underlying panels are joined to the wheel arch panel. For existing elongated holes, the front sheet metal edge is welded to the panel underneath.
5. Grinding and Finishing: The weld seam on the elongated hole is ground down. The area is then cleaned and painted using primer.
6. Reassembly: The vehicle is reassembled, and the repair is verified.

Technicians are advised to review and follow additional repair instructions listed in ISTA/AIR documents 41 04 100, 41 02 300, 41 05 701, 41 05 321, and 41 05 202 before welding and grinding.

Important Warnings

• G26 BEV vehicles are NOT affected! Owners of G26 Battery Electric Vehicles do not need to be concerned about this specific issue.
• No parts are needed. This repair primarily involves labor and materials for reworking existing components, meaning no new parts are required.

Warranty Information

This repair, identified by repair code 4114030100, is covered under the terms of the BMW New Vehicle Limited Warranty for Passenger Cars and Light Trucks. Dealers will use labor operation codes such as 41 00 009, 00 58 500, or 00 58 000 for diagnosis and repair. For specific procedures regarding diagnosis work time, technicians should refer to SI B01 01 20 or B01 07 20. Sublet repair for the rework of the rear upper section of the wheel arch panel is also covered.

Source: NHTSA ID: 11022101, SIB 41 07 25