2022 BMW 540I

Recalls

1 recall names the 2022 BMW 540I. Newest first.

• Power train › Driveline › Driveshaft

  Aug 12, 2026NHTSA 26V52500036,823 vehicles

  BMW of North America, LLC (BMW) is recalling certain 2020-2026 840i, 840i xDrive, 2021-2023 540i, 540i xDrive, M550i xDrive, and 2024-2026 750e xDrive vehicles. The connection between the driveshaft and the rear differential may become damaged, possibly resulting in a loss of power to the rear wheels or a vehicle rollaway.

  Risk and remedy

  Risk

  An unexpected loss of drive power can increase the risk of a crash. In addition, a damaged driveshaft can result in a vehicle rollaway if the parking brake is not applied, increasing the risk of a crash or injury.

  Remedy

  Dealers will inspect the connection between the driveshaft and rear axle differential, and apply adhesive or replace the driveshaft and rear axle differential, as necessary, free of charge. Owner notification letters were mailed October 8, 2026. Owners may contact BMW customer service at 1-800-525-7417. Vehicle Identification Numbers (VINs) involved in this recall will become searchable on NHTSA.gov beginning October 2, 2026.

  Full recall details →

Owner complaints

What owners report most

1. Power train4
2. Fuel/propulsion system2
3. Air bags1
4. Electrical system1
5. Engine1
6. Seat belts1

Latest complaints

• Sep 2, 2026CA
  Power train › Driveline › Differential unit

  See attached Petition letter for complaint.

• Aug 31, 2026NJ
  Power train
  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…

  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)

• Aug 31, 2026NY
  Power train
  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…

  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.

• Feb 5, 2026MA
  Fuel/propulsion system · Power train
  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…

  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.

• Aug 2, 2025TX
  Air bags · Seat belts

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

• Mar 22, 2023CACrash1 injury
  Electrical system · Engine · Fuel/propulsion system
  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…

  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.

Defect investigations

NHTSA’s Office of Defects Investigation opened these reviews into vehicles including this one.

• Driveshaft to rear differential connection failure

  DP26009Opened Sep 14, 2026Closed Oct 26, 2026
  The Office of Defects Investigation (ODI) received a petition on September 1, 2026 (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…

  The Office of Defects Investigation (ODI) received a petition on September 1, 2026 (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. On August 12, 2026, BMW filed Safety Recall 26V525, which addresses the same condition raised in the petition. and covers certain 2022-2026 840i, 840i xDrive, 2021-2023 540i, 540i xDrive, M550i xDrive, and 2024-2026 750e xDrive vehicles.  This safety recall addresses potential wear in the connection between the rear driveshaft and rear differential, which could cause the connection to fail. The Vehicle Identification Number included in the petition falls within BMW’s recall scope and subject to BMW’s reimbursement program. Because Safety Recall 26V525 fully addresses the concerns raised in the petition, further investigation is unnecessary. Therefore, ODI is denying this Defect Petition and closing this action. The agency will continue to monitor the remedy and reserves the right to take any action if warranted by future circumstances. To review the ODI reports cited in the Closing Resume ODI report Identification Number document, go to NHTSA.gov.

• Pedestrian alert sounds

  DP22005Opened Jan 27, 2023Closed Aug 7, 2023Recall 22V063000
  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…

  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.

Service bulletins

Technical service bulletins and other communications the manufacturer sent dealers about this vehicle. Ask a dealer for the full document by its number.

• 10252038Check 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.
• 10252031One or more of the LED daytime running lights are dim or discolored.
• 10249437The basic conditions for initializing the power windows are not met.
• 10249032The Central Information Display goes black intermittently due to resets of the Head Unit (HU-H3). FaultB7F8F9 HU-H: Reset will be stored in the HU-H3.
• 10249027The 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.
• 10249018At 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.
• 10249017SITUATION Unusual noises occur only when operating the steering column in the axial direction. 1. A one-time thump sound at the start of movement Shortly after the steering column starts moving, retracting, or extending, a one-time thump noise is heard. See attached video V32 03 23 2. Humming noise while steering column extends in the axial direction. The sound is only heard when the steering column is extended, not when the steering column is retracted. When the steering column starts to move in the extended direction, the humming noise can be heard. See attached video V32 04 23
• 10247567Engine will crank but not start. There is no communication with the integrated fuel module (TFE) whendiagnosing with ISTA. The following two fault codes will be stored in the DME: 032B43 - Low fuel pressure system, electric fuel pump: pressure value too low CDA594 - Message (- 0x33E) missing, receiver DME, transmitter TFE
• 10245422Customers may state that the alarm system (DWA) is not active after locking their unoccupied vehicle. Depending on the vehicles equipment and settings, no acoustic or optical confirmation (folding the mirrors/blinking confirmation) is noticeable. Additionally, the red anti-theft alarm LED in the interior mirror does not briefly flash every 2 seconds, indicating the alarm is armed.
• 10245367Check 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.
• 10244243Upon performing a vehicle read out, faultcode (CD0D16- Control unit light (BEL)(LIN): Wrong variant installed) is stored inthe BCP (Basic Central Platform). Note: Functionality of the exterior lights and switch is fully operational when fault code is present.
• 10242698?The sunroof will not operate in either direction.
• 10242694?The front seat will not calibrate/initialize, and the stored faults cannot be deleted.
• 10242691?Unusual noises occur only when operating the steering column in the axial direction.
• 10242688?A software error may cause an unwanted pressure pulsation in the transmission during a "Remote Engine Start."
• 10239614The air conditioning cycles from cold to warm air while driving or while at a stand still. The vent outlet temperatures vary by 25 degrees Fahrenheit or more (38 F to 60 F +) without changing any climate control settings.
• 10239611Headlight check control (CC) message 128 "High beam headlight failure" is displayed. The following fault codes are stored during a vehicle test: 80419A - Left high-beam headlight: Short circuit and/or 8041A5 - light outputs: Number of permitted short circuit cycles exceeded
• 10239603BMW AG has issued an Emissions Recall (effective March 17, 2023) on a certain Model Year 2021 - 2023 BMW vehicles that were produced between June 16, 2020, and December 13, 2022. Due to a software failure, there is the possibility that the transmission does not go into "sleep mode" if the car is turned off.
• 10239602A vehicle arrives at your center to be diagnosed for a micro-leak in the fuel evaporative (EVAP) system (NVLD natural vacuum leak detection). For this condition, the following fault is stored in the DME: 190302 - fuel tank ventilation and scavenging air system, micro-leak: leakage more than 0.5 mm.
• 10239601BMW AG has issued a Delivery Stop effective June 6, 2023 on certain Model Year 2023 - 2024 BMW vehicles that were produced between October 26, 2022 and May 8, 2023.
• 10239599With the introduction of the BMW Remote Software Upgrade, all Service Pack 18 vehicles and partial Service Pack 15 vehicles may receive new functionality or modifications in their features.
• 10238090After programming the head unit (HU-H2), activating the FSC (German word Freischaltcode) Enabling Codes repeatedly fails.
• 10238083Due to a software error, the vehicle sporadically does not achieve sleep mode. As a result, the 12-volt battery becomes discharged and may cause a no-start condition.
• 10238081Upon opening and closing the tailgate, a creaking/groaning sound can be heard from tailgate actuator.
• 10236387Engine Variants Updated.
• 10236236Issues with the various functions of the camera-based driver assistance systems (KAFAS system) can possibly lead to following customer complaints: KAFAS camera system deactivates itself, due to system restrictions that are not clear to the customer KAFAS camera system cannot be activated due to system restrictions that are not clear to the customer Road signs are sporadically not detected.
• 10235206Customer is shown an incorrect GPS location in the vehicle (i.e., Nav Map, coordinates).
• 10235205The 3G network in the US has been shut down. This means that only the 4G network will be available. In the 4G network, voice calls will be transferred via the Voice over LTE (VoLTE) function. For this purpose, the SIM card must perform an IMS registration in the mobile communication network. Due to a production error, the telematics control units were delivered without an IMS configuration. The Connected Drive voice services (Concierge Call, BMW Assistance, and emergency call voice) can no longer be used regionally in the US in vehicle with telematics control units ATM-1 and TCB-4G. Voice control of the vehicle and all other telephone (paired mobile devices) functions are not affected. Emergency call location data is unaffected.
• 10235203Customer states there is no audio playback (telephony, navigation, radio) and system sounds (PDC, turn indicators, acoustic signals) may also have failed.
• 10235200One or more of the LED daytime running lights are dim or discolored.
• 10235191Due to a software error, the vehicle sporadically does not achieve sleep mode. As a result, the 12-volt battery becomes discharged and may cause a no-start condition.
• 10235181A groaning type noise is heard during the height adjustment.
• 10235179There is a howling or whistling noise from under the vehicle at 30 -37 mph (50 -60 km/h) when driving after a cold start, when the outside temperature is 32 F (0 C) or lower.
• 10235178BMW AG has issued a Delivery Stop: Due to a software failure, there is the possibility that the transmission does not go into "sleep mode" if the car is turned off.
• 10233157There is a howling or whistling noise from under the vehicle at 30 -37 mph (50 -60 km/h) when driving after a cold start, when the outside temperature is 32 F (0 C) or lower. The noise goes away as the vehicle/driveline reaches operating temperature.
• 10230740Customer is shown an incorrect GPS location in the vehicle (i.e., Nav Map, coordinates).
• 10230734Due to a software error, Remote Software Upgrade (RSU) and Remote Support are currently not possible. Additionally, the Integrated Owner's Handbook cannot be displayed.
• 10230732The saved steering column positions, vertical and horizontal, are not stored long term.
• 10230726There is a howling or whistling noise from under the vehicle at 30 -37 mph (50 -60 km/h) when driving after a cold start, when the outside temperature is 32F (0C) or lower.
• 10230725A cracking, metallic noise from under the center of the vehicle.

Every BMW 540I model year

Bars are owner complaints, dots mark years with recalls. Select a year to open its report.