1999 BMW 540i recalls & complaints
Source: NHTSA, updated daily. Last checked 2026-10-18. Recalls apply to specific VINs — run your VIN to confirm.
1 safety recall, most serious first
1. Electrical system
What's wrong, in plain English: Wiring, modules, batteries. Short circuits can cause stalls or fires. VEHICLE DESCRIPTION: PASSENGER VEHICLES. THE THICKNESS OF THE MAIN POSITIVE ELECTRICAL CABLE (GENERATOR TO STARTER) INSULATION IS LESS THAN SPECIFIED, MAKING IT SUSCEPTIBLE TO BEING ABRADED OR CUT BY THE CLIP THAT SECURES THE CABLE TO THE GENERATOR.
What could happen: THE CABLE INSULATION CAN BE WORN AWAY, EXPOSING THE WIRE. THE WIRE COULD CONTACT THE CLIP OR A SHORT CIRCUIT COULD OCCUR.
The fix: DEALERS WILL APPLY A THICKNESS OF INSULATING TAPE TO THE CABLE IN THE AREA OF THE CLIP, AND INSTALL A REVISED CLIP.
What to do
- Check whether your car is affected: enter your 17-digit VIN at nhtsa.gov/recalls. A recall covers specific VINs, not every 1999 540I.
- Book a repair at any authorized BMW dealer. Quote NHTSA campaign 99V004000.
- The repair is free. By US law, safety recall repairs cost the owner nothing, no matter the car's age or mileage.
- Buying this car used? Ask the seller for proof the recall was completed, or run the VIN yourself before paying.
Official wording from NHTSA
Component: ELECTRICAL SYSTEM:12V/24V/48V BATTERY:CABLES
Summary: VEHICLE DESCRIPTION: PASSENGER VEHICLES. THE THICKNESS OF THE MAIN POSITIVE ELECTRICAL CABLE (GENERATOR TO STARTER) INSULATION IS LESS THAN SPECIFIED, MAKING IT SUSCEPTIBLE TO BEING ABRADED OR CUT BY THE CLIP THAT SECURES THE CABLE TO THE GENERATOR.
Consequence: THE CABLE INSULATION CAN BE WORN AWAY, EXPOSING THE WIRE. THE WIRE COULD CONTACT THE CLIP OR A SHORT CIRCUIT COULD OCCUR.
Remedy: DEALERS WILL APPLY A THICKNESS OF INSULATING TAPE TO THE CABLE IN THE AREA OF THE CLIP, AND INSTALL A REVISED CLIP.
Notes: OWNER NOTIFICATION BEGAN FEBRUARY 26, 1999. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT BMW AT 1-800-831-0117. ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).
Useful for owners
- OBD2 code reader — see what the car's computer is reporting
- Portable jump starter
- 1999 BMW 540i owner's manual
Owner complaints filed with NHTSA
Most complained-about parts: Engine (6), Electrical system (4), Brakes (4), Transmission / drivetrain (3), Steering (3).
Complaints are unverified reports from owners. A pattern (many complaints about the same part) matters more than any single one.
Read recent complaints (8)
07/08/2015 · Electrical system
TL* THE CONTACT OWNS A 1999 BMW 540I. THE CONTACT STATED THAT THE VEHICLE FAILED TO START. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC, WHERE IT WAS DIAGNOSED THAT THE POSITIVE BATTERY CABLE WAS BURNED. THE VEHICLE WAS REPAIRED. THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 99V004000 (ELECTRICAL SYSTEM). THE MANUFACTURER WAS MADE AWARE OF THE…
03/27/2015 · Transmission / drivetrain
TL*THE CONTACT OWNS A 1999 BMW 540I. THE CONTACT STATED THAT WHILE DRIVING AT 35 MPH, THE VEHICLE ACCELERATED WITHOUT WARNING AND HESITATED WHEN SHIFTING THE GEAR. THE FAILURE RECURRED SEVERAL TIMES. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC, WHO DIAGNOSED THAT THE TRANSMISSION NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS…
03/20/2015 · Airbags
MY 1999 BMW 540I WAS JUST SITTING IN THE DRIVEWAY AND WE HEARD A LOUD THUD. I WALKED OUT TO THE BMW AND NOTICED THE PASSENGER AIRBAG HAD DEPLOYED FOR NO REASON, SHATTERING THE WINDSHIELD. IF THIS HAD HAPPENED WHILE DRIVING, IT COULD HAVE CAUSED A SERIOUS ACCIDENT. *TR
05/13/2014 · Transmission / drivetrain
MY TRANSMISSION WOULD NOT ACCELERATE OR MOVE. I HAD THE TRANS REBUILD AND 2 YEARS LATER THE SAME PROBLEM. THE TRANS HAS LOST GEARS 1-3 AND REVERSE, MULTISTATE REPAIRED THE TRANS AGAIN 2013, IFOR THE SECOND TIME, IT NEVER WORKED AFTER REPAIRS. THE ENGINE LIGHT STAYS ON, BMW SAYS I NEED NEW TRANS AND ENGINE. WHEN I LOOKED UP RECALLS FOR 540I, IT STATES T…
11/27/2013 · Steering
POWER STEERING PUMP BROKE CAUSING ACCESSORY BELT TO BE THROWN FROM ENGINE AT HIGHWAY SPEEDS, RESULTING IN LOSS OF STEERING AND POWER. *TR
03/26/2011 · Steering
VEHICLE WAS DRIVEN AT HIGHWAY SPEED (55-60MPH) AND A LOUD METALLIC 'THUNK' NOISE WAS HEARD AS IF SOMETHING STRUCK OR BOUNCED OFF THE UNDERSIDE OF THE CAR. THE SERPENTINE DRIVE BELT WAS DISCOVERED TO HAVE COME OFF THE DRIVE PULLEYS, AND UPON CLOSER INSPECTION THE POWER STEERING PUMP WAS DISCOVERED TO BE LOOSE. THE UPPER MOUNTING EAR WAS BROKEN, AND THE LOW…
11/18/2010 · Latches / locks
TL*THE CONTACT OWNS A 1999 BMW 540I. THE CONTACT STATED THAT THE REAR DRIVERS SIDE DOOR WAS UNABLE TO OPEN FROM THE INSIDE AND OUTSIDE. THE VEHICLE WAS INSPECTED BY A DEALER WHO INFORMED THE CONTACT THAT THE DOOR LOCK ACTUATOR HAD FAILED. THE VEHICLE WAS REPAIRED. THE FAILURE MILEAGE WAS 135,000.
08/21/2010 · Steering
STARTED MY CAR AND HEARD A THUMPING NOISE AND FOUND OUT IT WAS MY BELT BEING CHEWED UP BECAUSE THE POWER STEERING PUMP BRACKETS BROKE. *TR