RecallScanner Severity Profile

BMW 540I

Watch11 recall campaigns, verify by VIN.

RecallScore

Critical

Fire risk

Crash risk

Injuries

Deaths

Check your specific 540I

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All Recalls

11 campaigns, model years 2017 to 2024

11 recalls 1 critical🔥 2 fire risk💥 10 crash risk

Model year

Airbag

Apr 29, 2020

2379 days ago

Your head airbag may fail to deploy in a crash or send the igniter flying into the cabin.

Affected: AIR BAGS · 2017

FIRE RISKCRASH RISK

NHTSA

Summary

BMW of North America, LLC (BMW) is recalling certain 2017 530i, 530i xDrive, 540i and 540i xDrive and 2017-2018 530e xDrive vehicles. Prior exposure to excessive levels of humidity within the driver and passenger head air bag inflators may affect the proper deployment of the head air bags.

Consequence

In the event of a crash of sufficient severity, deployment of the head air bag may be impaired and/or the igniter could separate from the inflator, increasing the risk of injury.

Remedy

BMW will notify owners, and dealers will replace the left or right head air bag, free of charge. The recall began June 24, 2020. Owners may contact BMW customer service at 1-800-525-7417.

Other

Aug 12, 2026

83 days ago

An unexpected loss of drive power can increase the risk of a crash.

Affected: POWER TRAIN:DRIVELINE:DRIVESHAFT · 2023

CRASH RISK

NHTSA

Summary

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.

Consequence

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.

Seat Belts

Jul 21, 2021

1931 days ago

Your passenger seat belt can fail to lock during a crash and increase injury risk.

Affected: SEAT BELTS · 2021

CRASH RISK

NHTSA

Summary

BMW of North America, LLC (BMW) is recalling certain 2021 2 Series (230i, 230i xDrive, M240i, M240i xDrive), 330e, 330e Xdrive, 4 Series Coupe (430i, 430i xDrive, M440i xDrive) M4 Coupe, M4 Competition Coupe, BMW 4 Series Convertible (430i, M440i), BMW X1 sDrive28i, xDrive28i, 2 Series Gran Coupe (228i, 228i xDrive, M235i xDrive), M2 Competition Coupe, 330i, 330i xDrive, M340i, M340i xDrive, M3, M3 Competition, 530i, 530i xDrive, 540i, 540i xDrive, MINI Hardtop 2 Door (Cooper, CooperS, JCW), X2 sDrive28i, X2 xDrive28i, X2 M35i, Z4 sDrive30i, Z4 M40i, MINI Hardtop 2 Door (Cooper SE), MINI Convertible (Cooper, Cooper S, JCW), MINI Clubman (Cooper S, Cooper S All4, JCW), MINI Countryman (Cooper, Cooper All4, Cooper S, Cooper S All4, JCW All4), Rolls Royce Ghost, MINI Countryman (Cooper S E All4), Rolls Royce Phantom, Rolls Royce Cullinan, and Toyota Supra vehicles. The passenger seat belt Automatic Locking Retractor (ALR) may deactivate early, before the webbing fully retracts. As such, these assemblies fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 208, "Occupant Crash Protection."

Consequence

During a crash, a seat belt retractor that does not function as intended increases the risk of injury.

Remedy

Dealers will inspect the seat belt retractors (including the seat belts) and, if necessary, replace the retractors, free of charge. Owner notification letters were mailed on September 3, 2021. Owners may contact BMW customer service at 1-800-525-7417; 1-866-825-1525 (MINI); 1-877-877-3735 (Rolls Royce); and 1-888-270-9371 (Toyota).

Software

Feb 19, 2021

2083 days ago

Your rearview camera can show a partial or blank image, blocking your view when backing up.

Affected: BACK OVER PREVENTION: SENSING SYSTEM: CAMERA · 2021

CRASH RISK

NHTSA

Summary

BMW of North America, LLC (BMW) is recalling certain 2019-2021 X3 sDrive30i, X3 xDrive30i, X3 M40i, X3M, X4 xDrive30i, X4 M40i, M550i, X4M, X5 sDrive40i, X5 xDrive40i, X5 xDrive50i, X5M, X5 M50i, X7 xDrive40i, X7 xDrive50i, X7 M50i, Alpina XB7, 330i, 330i xDrive, M340i, M340i xDrive, and 8 Series Coupe, Convertible and Grand Coupe, 840i, 840i xDrive, M850i xDrive, M8, 2020-2021 530e, 530e xDrive, 330e, 330e xDrive, 745Le, 745Le xDrive, X5 xDrive45e, X3 xDrive30e, X6 sDrive40i, X6 xDrive40i, X6 xDrive50i, X6 M50i, X6M, 530i, 530i xDrive, 540i, 540i xDrive, M550i xDrive, M5, 740i, 740Li, 740Li xDrive, M760i Drive, M760Li xDrive, 750Li xDrive Alpina, Alpina B7 xDrive, and 2021 4 Series Coupe 430i, 430i xDrive, M440i xDrive vehicles. When shifting into Reverse, a small portion of the rearview image may be obscured, or the screen may not illuminate. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 111, "Rear Visibility."

Consequence

If the driver relies on only the rearview camera image, the missing or reduced rearview image view can increase the risk of a crash or injury.

Remedy

BMW will notify owners, and dealers will inspect the rearview camera software and update it if necessary, free of charge. The recall began April 16, 2021. Owners may contact BMW customer service at 1-800-525-7417.

Software

Sep 30, 2020

2225 days ago

Your rearview camera can show a partially obscured image and blind you to vehicles or pedestrians behind you.

Affected: BACK OVER PREVENTION: SENSING SYSTEM: CAMERA · 2021

CRASH RISK

NHTSA

Summary

BMW of North America, LLC (BMW) is recalling certain 2020-2021 X3 sDrive 30i, X3 xDrive 30i, X3M 40i, X3 xDrive 30e, X4 xDrive 30i, X4M 40i, 530i, 540i, 540i xDrive, M550i xDrive, M5, 550e, 550e xDrive, and 550e iPerformance vehicles. A small portion of the rearview image may be slightly obscured. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 111, "Rear Visibility."

Consequence

If the driver relies on only the rearview camera image, the reduced rearview image view can increase the risk of a crash or injury.

Remedy

BMW will notify owners, and dealers will inspect and, if necessary, program the rearview camera with updated software. The recall began November 18, 2020. Owners may contact BMW customer service at 1-800-525-7417.

Other

Sep 18, 2024

776 days ago

Your brakes can fail, making it harder to stop and easier to lose control and crash.

Affected: ELECTRONIC STABILITY CONTROL (ESC):CONTROL MODULE · 2024

CRASH RISK

NHTSA

Summary

BMW of North America (BMW) is recalling certain 2023-2024 X1, 2024-2025 X5, 2025 X6, 2023-2025 X7, 740i, 760i, 2024 XM, 530i, 540i, i7, 750e, X2, 2024-2025 i5, 2024 Rolls Royce Spectre, 2025 MINI Countryman S ALL4, JCW Countryman ALL4, and 2025 MINI Hardtop 2 Door (Cooper, Cooper S) vehicles. Please refer to the recall report for the complete list of models. The welds in the servomotor of the integrated brake control module may break, causing a loss of power brake assist and rear brake function. In addition, the Antilock Brake System (ABS) and Dynamic Stability Control (DSC) system may not function.

Consequence

A loss of brake power assist or rear brake function can result in extended stopping distance. A loss of ABS or DSC can cause a loss of vehicle handling and control. Either of these scenarios can increase the risk of a crash.

Remedy

Dealers will replace the integrated brake system, free of charge. Owner notification letters were mailed November 13, 2024. Owners can contact BMW Customer Service at 1-800-525-7417.

Engine

Aug 2, 2021

1919 days ago

Your brakes can lose power assist when starting the engine, making it harder to stop.

Affected: ENGINE · 2020

CRASH RISK

NHTSA

Summary

BMW of North America, LLC (BMW) is recalling certain 2020 M340i, M340i xDrive, 540i, 540i xDrive, X3 M40i, 2020-2021 X4 M40i, 745Le xDrive, 2019-2021 Z4 M40i, and 2020-2021 Toyota Supra vehicles. During engine start, the engine management software may cause loss of braking assist. Full mechanical braking (without assist) remains available.

Consequence

Loss of braking assist can increase the risk of a crash.

Remedy

Dealers will update the engine management software, free of charge. Owner notification letters were mailed on September 17, 2021. Owners may contact BMW customer service at 1-800-525-7417.

Other

Feb 3, 2021

2099 days ago

Your output shaft can break and cause you to lose power or your parked car to roll away.

Affected: POWER TRAIN:DRIVELINE:DRIVESHAFT · 2021

CRASH RISK

NHTSA

Summary

BMW of North America, LLC (BMW) is recalling certain 2020-2021 530i xDrive, 540i xDrive and 2021 740Li xDrive vehicles. The output shafts (left/right) which transfer power from the driveshaft to the rear wheels may break due to a heat treatment error during supplier production.

Consequence

A broken output shaft can lead to a loss of drive power or a rollaway condition in a parked vehicle (if the parking brake is not engaged), increasing the risk of a crash.

Remedy

BMW will notify owners, and dealers will replace the output shaft(s), free of charge. The recall began March 24, 2021. Owners may contact BMW customer service at 1-800-525-7417.

Software

Sep 28, 2019

2593 days ago

Your back-up camera display can turn off and stay off, blocking your view when reversing.

Affected: BACK OVER PREVENTION: SENSING SYSTEM: CAMERA · 2020

CRASH RISK

NHTSA

Summary

BMW of North America, LLC (BMW) is recalling certain 2018 540d, 2018-2020 530i, 530i xDrive, 540i, 540i xDrive, M550i xDrive, M5, 530e, 530e xDrive, X3 sDrive, X3 xDrive, X3 M40i, X3 M, and 2019-2020 X4 xDrive, X4 M40i, X4 M, X7 xDrive, X7 M50i, 740Li, 740Li xDrive, 750Li, 750Li xDrive, 8 Series Convertible and Coupe 840i, 840i xDrive, M850i xDrive, X5 sDrive, X5 xDrive, X5 M50i, X6 xDrive, X6 M50i, 330i, 330i xDrive, M340i, M340i xDrive, Z4 sDrive, Z4 M40i, 740Le xDrive and 745Le xDrive, 2018-2019 640i xDrive Gran Turismo and Rolls-Royce Phantom, 2019 M850i xDrive Gran Coupe and Rolls-Royce Cullinan and 2020 Toyota Supra vehicles. The back-up camera and display settings can be adjusted such that the rear view image is no longer visible and the system will retain that setting the next time the vehicle is placed in reverse. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 111, "Rearview Mirrors."

Consequence

The lack of an image in the back-up camera display increases the risk of a crash.

Remedy

BMW will notify owners, and dealers will update the back-up camera software, free of charge. The recall began November 8, 2019. Owners may contact BMW customer service at 1-800-525-7417 or Rolls-Royce at 1-877-877-3735. Toyota owners may contact Toyota customer service at 1-888-270-9371.

Engine

Jul 12, 2018

3036 days ago

Your crankshaft sensor can fail and stall the engine while driving.

Affected: ENGINE AND ENGINE COOLING:ENGINE · 2018

CRASH RISK

NHTSA

Summary

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.

Consequence

A vehicle stall can increase the risk of a crash.

Remedy

BMW will notify owners, and dealers will replace the crankshaft sensor, free of charge. The recall began September 6, 2018. Owners may contact BMW customer service at 1-800-525-7417.

Electrical

Dec 9, 2020

2155 days ago

Your 48-volt battery connection can overheat and cause an engine fire while driving.

Affected: ELECTRICAL SYSTEM:12V/24V/48V BATTERY · 2021

FIRE RISK

NHTSA

Summary

BMW of North America, LLC (BMW) is recalling certain 2021 M340i xDrive, M440i xDrive Coupe, 530i, 530i xDrive, 540i, 540i xDrive, 740Li, 740Li xDrive, 840i Gran Coupe, 840i xDrive Gran Coupe, X5 sDrive40i, X5 xDrive40i, X6 sDrive40i, X6 xDrive40i, and X7 xDrive40i vehicles. The connection between the 48-Volt battery and the starter-generator may not have been assembled properly, which can cause increased electrical resistance at the connections.

Consequence

Increased electrical resistance can increase the risk of a fire.

Remedy

BMW will notify owners, and dealers will inspect the connection between the 48-Volt battery and the starter-generator assembly, replacing it if necessary, free of charge. The recall is expected to begin April 12, 2021. Owners may contact BMW customer service at 1-800-525-7417.

›Owner complaints (5)

01/30/20252024 540I

SERVICE BRAKES, HYDRAULIC,ELECTRONIC STABILITY CONTROL (ESC)

See attached document for complaint.

11/15/20242024 540I

SERVICE BRAKES

I reserved this vehicle with a deposit on Oct. 26. At the time I was told the vehicle was under recall/stop sale for a brake issue and I would not be able to take delivery until the recall work was performed. On 11/5, I was able to purchase the vehicle after the repair work was done. After leaving the dealership, about a half mile down the road I received a message on the vehicle display which said "Brake fluid level low. Have the problem checked by the nearest service center." The message also advised that I could continue driving the vehicle. I returned to the dealership and the car was inspected for roughly 30 mins. The vehicle was released to me and the message was gone. I was advised that the vehicle probably needed brake fluid from the recall repair. On 11/7, while driving I received the same Brake fluid level low message from the vehicle. I contacted the dealership and drove to the dealership to have the vehicle looked at again. About a mile from the dealership, as I applied the brakes, the vehicle suddenly generated a number of messages including "Brake system malfunction, stop carefully. Do not continue driving". At this point the brake pedal fell to the floor. I was able to stop the vehicle by applying a large amount of force to the brake pedal and was able to get to a nearby parking lot. I was very lucky and I would have been unable to prevent a crash under many circumstances. The braking power was almost completely gone from the vehicle. I returned the vehicle to the dealership and they reversed the transaction. From what I read online, the symptoms I experienced were exactly the same as those who experienced the brake failure which led to the recall. This car was either not fixed correctly or (even worse) the BMW remedy for the recall suffers the same potential problem as the original recall. In the second case, I believe this is a very dangerous situation.

11/14/20242024 540I

BACK OVER PREVENTION,ELECTRICAL SYSTEM

See attached document for complaint.

10/29/20242024 540ICrash

BACK OVER PREVENTION,FORWARD COLLISION AVOIDANCE

PROBLEM: I recently had several incidents when the RAB (rear automatic brake) on the 2024 BMW 540i vehicle DID NOT WORK on multiple occasions. The vehicle never stopped as I backed out of my parking space. Afterwards I tested the RAB by perpendicularly slowly walking behind the car. I had to run out of the way when the vehicle was continuing to move when approximately 12” from me. I tested both vehicles, 540i & X-3, with the same results. As a further test I placed a plastic figure that’s ordinarily used a warning to drivers of children playing in the area. Results while slowly backing was that the vehicle hit (bumped) the little green “man”. I later discussed this issue with my wife that drives the 2024 X-3. She then informed me that she too almost backed into a pedestrian. I then did the same tests on my wife’s 2024 X-3, VIN [XXX] , with the exact same results. BMW of Wesley Chapel had no solution. I spoke with managers Doonan and Hernandez. I believe the photos demonstrate the slight graze of an item whereby the RAB should have stopped the car; it never should have allowed the collision. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

10/16/20242024 540I

SERVICE BRAKES, HYDRAULIC,ELECTRONIC STABILITY CONTROL (ESC)

The contact owns a 2024 BMW 540i. The contact received notification of NHTSA Campaign Number: 24V10400(Electronic Stability Control(ESC), Service Brakes, Hydraulic); however, the part to do the recall repair was not yet available. The local dealer was contacted. 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 the failure. VIN tool confirms parts not available.

Complaints are self-reported to NHTSA by owners and are not verified by the agency.

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Full analysis: how to read the BMW 540I recall history

Year range, common components, complaint patterns, and how to use this page.

Understanding the BMW 540I recall history

The BMW 540I currently has 11 recall campaigns and 5 owner complaints indexed from the NHTSA public database. Each recall represents a formal campaign to fix a defect at no cost to the current owner. Owner complaints are self-reported incidents that haven't (yet) resulted in a recall but can indicate emerging patterns worth watching.

The most frequent recall categories for the 540I in our dataset are software / sensor (3), engine (2), and seat belt (1). These clusters matter when you're shopping for a used 540I: recalls in these systems tend to be the ones most likely to have been skipped by previous owners, because they aren't always visible during a routine test drive or pre-purchase inspection.

The tracked recalls span model years 2017–2024, with campaigns reported to NHTSA between 2018 and 2026. Not every model year carries every recall. Each campaign is scoped to a specific year range and often a specific build window, which is why a VIN lookup is the only way to know whether a particular 540I is actually affected by any of these campaigns.

NHTSA's complaint database for the 540I records 1 crash report. Complaint data is unverified and shouldn't be read as a blanket condemnation of the model (large production volumes naturally produce more reports), but it is useful for spotting whether a specific defect has a serious real-world pattern behind it.

How to use this page

The safest path for an owner is to run your VIN through the checker above. A VIN query hits NHTSA's live API and tells you whether your specific 540I has an open, unresolved recall. If you're researching a used 540Ibefore buying, use the recall list below to understand the model's full history, then check the seller's VIN to see whether prior owners actually completed the free repairs. Many don't, and unresolved recalls can linger for years.

Figures are generated live from the RecallScanner dataset, which is sourced from NHTSA's public recall and complaint APIs and refreshed daily. RecallScanner is independent and not affiliated with BMW or any U.S. government agency.

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