BMW of North America, LLC (BMW) is recalling certain 2018 BMW 540d xDrive vehicles. The crankshaft sensor may be equipped with incorrect firmware, preventing the sensor from properly processing input from the crankshaft reluctor ring, possibly resulting in a vehicle stall. On September 12, 2018, BMW expanded the recall to a total of 5,309 vehicles including certain 2018-2019 BMW 540d xDrive, 230i M240i, M240i xDrive, X2 sDrive28i, X2 xDrive28i, X1 sDrive28i, X1 xDrive28i, 330i, 330i xDrive, 340i, 340i xDrive, 330i xDrive Gran Turismo, 530i, 530i xDrive, 540i, 540i xDrive, 530e, 530e xDrive, 640i xDrive Gran Turismo, 330e, 2019 430i Gran Coupe, 430i xDrive Gran Coupe, 440i Gran Coupe, 440i xDrive Gran Coupe, 430i, 430i xDrive, 440i, 440i xDrive, 740i, 740i xDrive, MINI Cooper, Cooper S, JCW, MINI Countryman (Cooper, Cooper All4, Cooper S, Cooper S All4, JCW All4), and MINI Clubman (Cooper, Cooper S, Cooper All4, Cooper S All4, JCW All4) vehicles.
Cannot open rear passenger side door from the inside. Front door passenger side door locking system has also failed and had to be replaced. Rear trunk lock has failed and has had to be replaced. The rear passenger side door is a major safety issue. I could not find any notice of recalls having to do with all of these locking problems.
No injuries · No fire · No crash
Rear brake light bulb housing assemblies melted plastic around metal bulbs contacts. Both tail light assemblies has failed three times each. Changing the bulb doesn't resolve the issue. When driving the car with the ECO start/stop on, the car will roll and then the car will stop and say "Transmission car not in park", and you have to put the car in park then turn the car back on. This has happened multiple times and is embarrassing
No injuries · No fire · No crash
When starting my car and moving it into the reverse position or drive it starts to sometimes stalls. It doesn't happen all the time but does happen. It tells me the car is not in park. I brought it to a shop and they said it's the crankshaft sensor and there is a recall for cars like mine but not my specific vin. The car shop had it happen to them as well and they confirmed it. No warnings before it happened.
No injuries · No fire · No crash
While driving a drivetrain warning ⚠️ was detected and code was displayed on the I drive, along with a CEL. The vehicle is in limp mode so I was unable to accelerate past 35-40 mph. Took the car into the dealership and was informed that my waste gate actuator failed @59,388 miles. The part is an electric controller and can fail without warning. In my opinion 59,000 miles is extremely early for a part that controls boost pressure at the turbocharger. Found numerous complaints about this component and I feel it should be recalled by the manufacturer. This component was an issue on older models and BMW extended the warranty to 15 years/150,00 miles.
No injuries · No fire · No crash
Water began accumulating in the front footwell area of the vehicle, resulting in a soaked carpet and persistent musty odor. The condition developed during normal operation of the air conditioning system, without any external water intrusion (no flooding or open windows). The issue appears to be caused by a failure of the A/C condensate drain system, which is not properly draining water outside the vehicle. Instead, condensation is leaking into the cabin. This creates a risk of mold growth and potential damage to electrical components located beneath the floor, including wiring harnesses and control modules. The problem has been reproducible, especially when the air conditioning is in use. There were no warning lights or alerts prior to noticing the issue. Research indicates that BMW has identified this exact defect in Service Information Bulletin SIB 64 04 16, which states that the condensate drain hose may be improperly installed, kinked, blocked, or damaged during installation, leading to water ingress into the footwell area. This suggests the issue is due to a known design or manufacturing defect rather than normal wear and tear. This condition poses a safety concern due to possible electrical malfunction and reduced vehicle reliability. The affected components are available for inspection upon request.
No injuries · No fire · No crash