2004 BMW 5-Series 545i Review

Summary: ZF Group North America Operations (ZF) is recalling certain Lemförder Steering Center Rods sold as aftermarket parts for 1996-2004 BMW 5-Series (E39) vehicles. The steering center rods may have an insufficient ball pin pull force that may allow the rods to detach from the steering knuckle.

Consequence: If the steering rod detaches from the steerable wheel knuckle, it can cause sudden loss of steering control, increasing the risk of a crash.

Remedy: ZF has notified the parts distributors, instructing them to inform the end customer. ZF will reimburse them for the affected parts. The recall began August 28, 2019.

Notes: Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

Summary: ZF Group North America Operations (ZF) is recalling certain Lemförder Steering Center Rods sold as aftermarket parts for 1996-2004 BMW 5-Series (E39) vehicles. The steering center rods may have an insufficient ball pin pull force that may allow the rods to detach from the steering knuckle.

Consequence: If the steering rod detaches from the steerable wheel knuckle, it can cause sudden loss of steering control, increasing the risk of a crash.

Remedy: ZF has notified the parts distributors, instructing them to inform the end customer. ZF will reimburse them for the affected parts. The recall began August 28, 2019.

Notes: Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

Summary: This recall involves aftermarket parts sold by Valeo. Valeo is recalling certain engine cooling fans, part numbers 696121, 696273, and 696275, used as service replacement parts for model year 2008-2011 BMW 1-Series, 2006-2011 BMW 3-Series, 2000-2009 BMW 5-Series, 2004-2005 BMW 6-Series, and 2006-2007 BMW 7-Series vehicles. A metal-oxide semiconductor may overheat due to insufficient screwing of the semiconductor on the aluminum heat sink. This primary failure could cause adjacent components on the fan assembly motor circuit board to overheat and short.

Consequence: This condition could cause the fan motor to become inoperative, or cause the motor circuit board in the assembly to overheat, potentially leading to a fire in the engine compartment.

Remedy: Valeo will notify owners and replace the fans free of charge. The safety recall began on August 22, 2012. This recall is being conducted by Valeo, not by BMW. For further information, owners may contact Valeo at 1-888-718-2536.

Notes: Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

Summary: BMW IS RECALLING CERTAIN MODEL YEAR 2004-2010 5-SERIES, MODEL YEAR 2004-2010 6-SERIES, MODEL YEAR 2006-2010 M5, AND MODEL YEAR 2007-2010 M6 VEHICLES. THE INSULATED BULKHEAD CONNECTOR FOR THE POSITIVE BATTERY CABLE MAY HAVE BEEN INCORRECTLY ATTACHED TO THE TRUNK FLOOR PANEL, WHICH CAN LEAD TO A LOOSENING OF THE BOLT CONNECTION. AS IT LOOSENS, AN INCREASE IN ELECTRICAL RESISTANCE AT THIS CABLE CONNECTION IS POSSIBLE AND COULD CAUSE THE CABLE CONNECTION TO OVERHEAT.

Consequence: OVERHEATING COULD LEAD TO A FIRE, EVEN WHILE THE VEHICLE IS NOT IN USE. AS A PRECAUTION, OWNERS ARE ADVISED TO PARK OUTSIDE UNTIL THE REMEDY HAS BEEN MADE.

Remedy: BMW WILL NOTIFY OWNERS, AND DEALERS WILL INSPECT AND SECURE THE BATTERY BOLT CABLE CONNECTION AS NECESSARY, FREE OF CHARGE. THE SAFETY RECALL BEGAN ON APRIL 30, 2012. OWNERS MAY CONTACT BMW CUSTOMER RELATIONS AND SERVICES AT 1-800-525-7417.

Notes: CUSTOMERS MAY CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY: 1-800-424-9153); OR GO TO HTTP://WWW.SAFERCAR.GOV.

Summary: BMW IS RECALLING CERTAIN MODEL YEAR 2004-2010 5-SERIES, 6-SERIES, AND MODEL YEAR 2002-2008 7-SERIES VEHICLES. A CHECK VALVE OF THE BRAKE VACUUM PUMP MAY LEAK A SMALL AMOUNT OF LUBRICATING OIL. OVER TIME THIS COULD RESULT IN CONTAMINATION OF THE BRAKE BOOSTER.

Consequence: POWER ASSIST BRAKING PERFORMANCE COULD BE ADVERSELY AFFECTED. IN EXTREME CASES THERE COULD BE A COMPLETE LOSS OF POWER ASSIST BRAKING. AN UNEXPECTED REDUCTION OR LOSS IN POWER BRAKING ASSIST MAY INCREASE THE RISK OF A CRASH.

Remedy: BMW WILL NOTIFY OWNERS AND DEALERS WILL REPAIR THE VEHICLES FREE OF CHARGE. THE SAFETY RECALL BEGAN ON NOVEMBER 24, 2010. OWNERS MAY CONTACT BMW AT 1-800-525-7417.

Notes: OWNERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO HTTP://WWW.SAFERCAR.GOV .

Summary: BMW IS RECALLING 200,000 MY 2006 3 SERIES SPORT SEAT, MY 2004-2006 5 SERIES STANDARD AND SPORT SEAT, AND MY 2004-2006 X3 PASSENGER VEHICLES. DEPENDING ON THE MANNER AND FREQUENCY OF THE FRONT PASSENGER'S ENTRY AND EXIT, SMALL CRACKS HAVE DEVELOPED IN THE MAT. IF THIS OCCURS, THE FRONT PASSENGER AIR BAGS, WITH THE EXCEPTION OF THE HEAD PROTECTION SYSTEM, WILL BE DEACTIVATED AND THE AIR BAG WARNING LAMP AS WELL AS THE PASSENGER AIR BAG "ON-OFF" LAMP WILL BE ILLUMINATED.

Consequence: IN THIS SITUATION THE FRONT PASSENGER AIR BAGS WILL NOT DEPLOY EVEN IF A SUFFICIENTLY SEVERE ACCIDENT WOULD OCCUR AND OCCUPANT PROTECTION PROVIDED BY THE SYSTEM WOULD NOT BE POSSIBLE.

Remedy: DEALERS WILL REWORK THE FRONT PASSENGER SEAT SENSOR MAT SO THAT EXTERNAL FORCE APPLICATION TO THE SEAT DOES NOT CAUSE A CRACK TO THE MAT. THE RECALL BEGAN ON NOVEMBER 6, 2008. BMW WILL ALSO EXTEND THE WARRANTY ON THESE VEHICLES TO 10 YEARS FROM FIRST REGISTRATION WITHOUT ANY MILEAGE LIMIT. OWNERS MAY CONTACT BMW AT 1-800-525-7417.

Notes: BMW IS EXTENDING THE WARRANTY TO 10 YEARS FROM FIRST REGISTRATION WITHOUT ANY MILEAGE LIMIT TO THE FOLLOWING VEHICLES:MY 2006 6-SERIES, 3-SERIES (STANDARD SEAT), MY 2004-2005 Z4, MY 2004-2006 7-SERIES, MY 2006 X5, AND MY 2004-2006 5-SERIES (COMFORT SEAT).UNDER THE EXTENDED WARRANTY PROGRAM, THE OCCUPANT DETECTION MAT IN A VEHICLE THAT EXPERIENCES THIS SPECIFIC ISSUE WILL BE REPLACED AT NO CHARGE TO THE CUSTOMER.CUSTOMERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO HTTP://WWW.SAFERCAR.GOV.

Summary: ON CERTAIN PASSENGER VEHICLES EQUIPPED WITH FRONT SEAT HEATING SYSTEMS, UPON ENTERING AND EXITING THE VEHICLE, EXCESSIVE CONTACT WITH THE SIDE BOLSTER THAT IS CONTAINED IN THE SEAT'S BACKREST MAY DAMAGE THE HEATING MAT LOCATED IN THIS AREA. IF SUCH DAMAGE WERE TO OCCUR, WITH THE SYSTEM TURNED ON, THE VEHICLE OCCUPANT MAY FEEL EXCESSIVE HEAT FROM THIS AREA.

Consequence: IT IS POSSIBLE THAT THE HEATING MAT IN THE BACKREST'S SIDE BOLSTER COULD OVERHEAT AND DAMAGE, OR MELT A SMALL HOLE IN, THIS AREA OF THE SEAT COVER. IF THIS HAPPENED, IT COULD LEAD TO AN OCCUPANT BEING BURNED.

Remedy: DEALERS WILL MODIFY THE SEAT HEATING CIRCUIT. THE RECALL IS EXPECTED TO BEGIN DURING DECEMBER 2004. OWNERS SHOULD CONTACT BMW AT 1-800-831-1117.

Notes: CUSTOMERS CAN ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).

Summary: ON CERTAIN PASSENGER VEHICLES EQUIPPED WITH 8 AND 12 CYLINDER ENGINES, THE DIGITAL ENGINE MANAGEMENT CONTROL (EMC) UNITS WERE NOT PRODUCED ACCORDING TO SPECIFICATIONS.

Consequence: AS A RESULT, ENGINE STALLING WILL OCCUR AFTER A SHORT PERIOD OF OPERATION. THE VEHICLE MAY NOT BE ABLE TO RESTART. ALSO, A LOSS OF POWER STEERING AND, AFTER REPEATED ACTUATION OF THE BRAKE PEDAL, A LOSS OF BRAKE POWER ASSIST WILL OCCUR. THESE CONDITIONS COULD RESULT IN A VEHICLE CRASH.

Remedy: DEALERS WILL INSTALL A NEW DIGITAL ENGINE MANAGEMENT CONTROL UNIT. THE RECALL BEGAN ON JULY 16, 2004. OWNERS SHOULD CONTACT BMW AT 1-800-831-1117.

Notes: CUSTOMERS CAN CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).

Summary: ON CERTAIN PASSENGER VEHICLES EQUIPPED WITH 8-CYLINDER ENGINES, A CIRCULAR RETENTION CLIP AT THE QUICK-RELEASE COUPLING ALONG THE FUEL SUPPLY LINE WAS INADVERTENTLY NOT INSTALLED.

Consequence: IN THE EVENT OF A SEVERE FRONTAL CRASH, THE QUICK-RELEASE COUPLING COULD SEPARATE CAUSING FUEL LEAKAGE. FUEL LEAKAGE, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE.

Remedy: DEALERS WILL INSTALL A CIRCULAR RETENTION CLIP AT THE QUICK-RELEASE COUPLING ALONG THE FUEL SUPPLY LINE. THE RECALL BEGAN ON JULY 5, 2004. OWNERS SHOULD CONTACT BMW AT 1-800-831-1117.

Notes: CUSTOMERS CAN ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).