Total Complaints
29 filings
BMW 540I · model year
29 NHTSA complaints, 1 crash report for this specific cohort.
NHTSA overall rating
Not crash-tested
New Car Assessment Program
The 1999BMW540I carries 29 consumer safety complaints in NHTSA's Office of Defects Investigation database for this specific model-year cohort. Within that volume, owners reported 1 crash, 0 fires, 0 injuries, and 0 fatalities. No NCAP 5-star crash-test rating is available for this model year in the federal database.
Component-level analysis is where model-year complaints become actionable: the top complaint category for the 1999 540I is electrical system with 4 filings, followed by engine and engine cooling:cooling system:radiator assembly (3) and steering (3). Concentration in one or two component groups is the classic signature of a systemic defect; a flat distribution usually reflects normal aging, warranty complaints, or isolated build-plant variability.
NHTSA currently has 34 investigation files overlapping the 1999 540I. Owners comparing this cohort against neighboring years should pair the counters above with the complaint-by-year trend on the parent model page — a spike in a single year often tracks to a platform refresh, a new transmission supplier, or an updated ECU calibration. Use the related-complaint feed below to read raw owner narratives before deciding whether any pattern here affects your specific use case.
Total Complaints
29 filings
Crashes Reported
1 reports
Source
NHTSA ODI
Federal complaints database
At or below the fleet median complaint volume.
| Component | Count |
|---|---|
| ELECTRICAL SYSTEM | 4 |
| ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY | 3 |
| STEERING | 3 |
| POWER TRAIN:AUTOMATIC TRANSMISSION | 2 |
| ENGINE AND ENGINE COOLING:COOLING SYSTEM | 2 |
| SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP | 2 |
| LATCHES/LOCKS/LINKAGES | 2 |
| AIR BAGS:SIDE/WINDOW | 1 |
| TIRES:TREAD/BELT | 1 |
| SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP:CONTROL UNIT/MODULE | 1 |
| ELECTRONIC STABILITY CONTROL:AUTOMATIC (ASC) | 1 |
| ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL | 1 |
| ELECTRONIC STABILITY CONTROL (ESC) | 1 |
| SERVICE BRAKES | 1 |
| ENGINE | 1 |
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 FAILURE. THE FAILURE MILEAGE WAS 147,076.
Mileage: 147,076
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 NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 160,000. UPDATED 6/8/15*CN UPDATED 10/3/1017*CN
Mileage: 16,000
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
Mileage: 189,000
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
Mileage: 189,000
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 THE SAME TRANS PROBLEM AND IT SHOULD BE REPLACED. WHEN I LOOK UP ENGINE THERE ARE KNOWN ENGINE PROBLEMS WITH 540I, NOT MY VIN. I ALSO HAVE ELECTRICAL ISSUES, WHICH HAVE A RECALL ON 540I, BUT NOT MY VIN. ALSO ISSUES WITH COOLANT, WHICH IS ANOTHER KNOWN ISSUE, BUT NOT MY VIN. I HAVE TRIED TO GET BMW TO DIAGNOSE, BUT THEY ONLY RECOMMEND REPLACING ALL PARTS AT MY EXPENSE, EVEN THOUGH THERE IS A HISTORY OF THESE TYPE OF ISSUES WITH THE 540I, 1999 CARS. I WANT BMW TO REPLACE ALL KNOW ISSUE PARTS AT THEIR EXPENSE AND THEY HAVE REFUSED DUE TO MY VIN, NOT WILLING TO ADD VIN TO THE ISSUE. ALL ISSUES WITH MY CAR ARE KNOWN ISSUES FOR 540I 1
Mileage: 70,000
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 THE SAME TRANS PROBLEM AND IT SHOULD BE REPLACED. WHEN I LOOK UP ENGINE THERE ARE KNOWN ENGINE PROBLEMS WITH 540I, NOT MY VIN. I ALSO HAVE ELECTRICAL ISSUES, WHICH HAVE A RECALL ON 540I, BUT NOT MY VIN. ALSO ISSUES WITH COOLANT, WHICH IS ANOTHER KNOWN ISSUE, BUT NOT MY VIN. I HAVE TRIED TO GET BMW TO DIAGNOSE, BUT THEY ONLY RECOMMEND REPLACING ALL PARTS AT MY EXPENSE, EVEN THOUGH THERE IS A HISTORY OF THESE TYPE OF ISSUES WITH THE 540I, 1999 CARS. I WANT BMW TO REPLACE ALL KNOW ISSUE PARTS AT THEIR EXPENSE AND THEY HAVE REFUSED DUE TO MY VIN, NOT WILLING TO ADD VIN TO THE ISSUE. ALL ISSUES WITH MY CAR ARE KNOWN ISSUES FOR 540I 1
Mileage: 70,000
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 THE SAME TRANS PROBLEM AND IT SHOULD BE REPLACED. WHEN I LOOK UP ENGINE THERE ARE KNOWN ENGINE PROBLEMS WITH 540I, NOT MY VIN. I ALSO HAVE ELECTRICAL ISSUES, WHICH HAVE A RECALL ON 540I, BUT NOT MY VIN. ALSO ISSUES WITH COOLANT, WHICH IS ANOTHER KNOWN ISSUE, BUT NOT MY VIN. I HAVE TRIED TO GET BMW TO DIAGNOSE, BUT THEY ONLY RECOMMEND REPLACING ALL PARTS AT MY EXPENSE, EVEN THOUGH THERE IS A HISTORY OF THESE TYPE OF ISSUES WITH THE 540I, 1999 CARS. I WANT BMW TO REPLACE ALL KNOW ISSUE PARTS AT THEIR EXPENSE AND THEY HAVE REFUSED DUE TO MY VIN, NOT WILLING TO ADD VIN TO THE ISSUE. ALL ISSUES WITH MY CAR ARE KNOWN ISSUES FOR 540I 1
Mileage: 70,000
POWER STEERING PUMP BROKE CAUSING ACCESSORY BELT TO BE THROWN FROM ENGINE AT HIGHWAY SPEEDS, RESULTING IN LOSS OF STEERING AND POWER. *TR
Mileage: 188,000
POWER STEERING PUMP BROKE CAUSING ACCESSORY BELT TO BE THROWN FROM ENGINE AT HIGHWAY SPEEDS, RESULTING IN LOSS OF STEERING AND POWER. *TR
Mileage: 188,000
POWER STEERING PUMP BROKE CAUSING ACCESSORY BELT TO BE THROWN FROM ENGINE AT HIGHWAY SPEEDS, RESULTING IN LOSS OF STEERING AND POWER. *TR
Mileage: 188,000
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 LOWER MOUNTING BOLT WAS MISSING ENTIRELY. IT APPEARS THE BREAK IN THE UPPER MOUNTING EAR CAUSE THE LOWER BOLT TO VIBRATE LOOSE, AND IN TURN THE SERPENTINE DRIVE BELT WAS DISLODGED. THE RESULT WAS SUDDEN LOSS OF POWER STEERING THAT NEARLY CAUSED AN ACCIDENT WHEN ATTEMPTING TO TURN AT LOW SPEED DUE TO SUDDEN AND UNEXPECTED INCREASE IN STEERING EFFORT.
Mileage: 176,009
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.
Mileage: 135,000
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
MY 1999 BMW 540I HAS HAD INTERMITTENT DOOR UNLOCKING FAILURES FOR SEVERAL YEARS. THE ANY OF THE FOUR DOORS MAY SUDDENLY BECOME DOUBLE LOCKED SO THAT NEITHER THE ELECTRONIC BUTTONS OR ANY MANUAL EFFORTS WILL UNLOCK/OPEN THE DOORS. FORTUNATELY NOT ALL OF THE DOOR LOCKS HAVE FAILED AT THE SAME TIME, SO OCCUPANTS HAVE BEEN ABLE TO CLIMB OVER AND BETWEEN SEATS TO EGRESS THE CAR. MECHANICS SAY THAT THE PROBLEM IS RELAYS IN THE GENERAL MODULE (GM III) WHICH CONTROLS ALL OF THE DOOR LOCKS. IN THE PAST THE PROBLEM WOULD SELF-CORRECT IN A FEW HOURS OR DAYS. TWO WEEKS AGO, ONE BACK DOOR FOLLOWED BY THE OTHER A COUPLE OF DAYS LATER LOCKED AND WON'T UNLOCK. APPARENTLY, THE CRASH SENSOR WHICH TELLS THE GM TO UNLOCK THE DOORS IN THE EVENT OF A CRASH WILL NOT WORK. THIS FAILURE TRAPS OCCUPANTS IN THE CAR. *TR
Mileage: 154,000
AT APPROXIMATELY 75K MILES THE BOSCH ABS/TRACTION CONTROL UNIT FAILED ON MY 1999 BMW 540I. A DIAGNOSIS FROM THE DEALER CONFIRMED THIS TO BE TRUE. A NEW UNIT WAS INSTALLED AT THE APPROX COST OF $600. WHAT IS TROUBLING IS THAT EVERY OWNER OF A BMW 5-SERIES FROM 1999-2000 SEEMS TO HAVE HAD THIS PART FAIL ON THEM. ACTUALLY, I HAVE YET TO MEET OWNER WHO STILL HAS THEIR ORIGINAL PART. BMW OF NORTH AMERICA WAS LESS THAN HELPFUL AND DENIED A WARRANTY CLAIM (CAR WAS OUT OF WARRANTY) AND DID NOT FEEL THAT THIS INTEGRAL CONTROL UNIT SHOULD BE RECALLED DESPITE STATISTICS THAT SHOW OTHERWISE. THIS APPEARS TO BE A SAFETY CONCERN SINCE THIS FAILURE LEAVES THE TRACTION CONTROL AND ABS SUDDENLY INOPERATIVE. *TR
MY SON WAS DRIVING HOME IN RUSH HOUR TRAFFIC ON CONNECTICUT AVE. IT WAS RAINING RATHER HARD AND VISIBILITY WAS LOW. MY SON ALL OF THE SUDDEN SMELLED SMOKE COMING THROUGH THE VENTS AND THE ENGINE SHUT DOWN. IT WOULD NOT RESTART. HE HAD TO PUSH IT OFF THE ROAD INTO A SERVICE STATION DUE TO THE HIGH VOLUME OF TRAFFIC. THE CAR WAS TOWED THAT EVENING TO MY REPAIR SHOP WHERE IT WAS DIAGNOSED THAT THE THERMOSTAT HOUSING SENSOR FAILED WHICH MELTED THE WIRING HARNESS AND DAMAGED OTHER ELECTRICAL SENSORS ON THE ENGINE. *TR
Mileage: 60,590
MY SON WAS DRIVING HOME IN RUSH HOUR TRAFFIC ON CONNECTICUT AVE. IT WAS RAINING RATHER HARD AND VISIBILITY WAS LOW. MY SON ALL OF THE SUDDEN SMELLED SMOKE COMING THROUGH THE VENTS AND THE ENGINE SHUT DOWN. IT WOULD NOT RESTART. HE HAD TO PUSH IT OFF THE ROAD INTO A SERVICE STATION DUE TO THE HIGH VOLUME OF TRAFFIC. THE CAR WAS TOWED THAT EVENING TO MY REPAIR SHOP WHERE IT WAS DIAGNOSED THAT THE THERMOSTAT HOUSING SENSOR FAILED WHICH MELTED THE WIRING HARNESS AND DAMAGED OTHER ELECTRICAL SENSORS ON THE ENGINE. *TR
Mileage: 60,590
THE DRIVER OWNS A 1999 BMW 540I WITH 72,579 MILES. OVER THE PAST TWO MONTHS THE DISC BMW ELECTRONIC STABILITY CONTROL SYSTEM ICON AND THE AMBER ABS AND BRAKE LIGHTS ILLUMINATED IN ONE OF TWO SCENARIOS: (1) JUST AFTER A NEW IGNITION CYCLE, (2) DURING NORMAL DRIVING. ONCE THESE WARNINGS ILLUMINATED THE DSC, ABS, AND TRACTION CONTROL SYSTEMS BECOME NON-FUNCTIONAL. UNTIL RECENTLY, THE WARNINGS WOULD GO OUT AFTER 5-10 IGNITION CYCLES. NOW THEY WERE ON CONTINUOUSLY.*AK NEXT TO SEATBELTS, I STRONGLY BELIEVE ESC IS THE MOST SIGNIFICANT DEVELOPMENT IN AUTOMOTIVE SAFETY. AS SUCH, I FIND IT VERY DISCONCERTING THE SYSTEM ON MY VEHICLE HAS MALFUNCTIONED. RESEARCHING THE TOPIC ON THE VARIOUS BMW FORUMS HAS LEAD ME TO BELIEVE MY SITUATION IS NOT AN ISOLATED ONE; THAT MANY MODEL YEAR 1999-2000 5-SERIES BMWS HAVE ALSO BEEN AFFECTED. ESC MALFUNCTIONS CAN HAVE VERY NEGATIVE IMPACT ON VEHICLE SAFETY. IN JUSTIFYING THE RATIONALE FOR ITS RECENT MANDATE OF ESC, NHTSA ESTIMATES ESC WILL RED
Mileage: 72,000
THE DRIVER OWNS A 1999 BMW 540I WITH 72,579 MILES. OVER THE PAST TWO MONTHS THE DISC BMW ELECTRONIC STABILITY CONTROL SYSTEM ICON AND THE AMBER ABS AND BRAKE LIGHTS ILLUMINATED IN ONE OF TWO SCENARIOS: (1) JUST AFTER A NEW IGNITION CYCLE, (2) DURING NORMAL DRIVING. ONCE THESE WARNINGS ILLUMINATED THE DSC, ABS, AND TRACTION CONTROL SYSTEMS BECOME NON-FUNCTIONAL. UNTIL RECENTLY, THE WARNINGS WOULD GO OUT AFTER 5-10 IGNITION CYCLES. NOW THEY WERE ON CONTINUOUSLY.*AK NEXT TO SEATBELTS, I STRONGLY BELIEVE ESC IS THE MOST SIGNIFICANT DEVELOPMENT IN AUTOMOTIVE SAFETY. AS SUCH, I FIND IT VERY DISCONCERTING THE SYSTEM ON MY VEHICLE HAS MALFUNCTIONED. RESEARCHING THE TOPIC ON THE VARIOUS BMW FORUMS HAS LEAD ME TO BELIEVE MY SITUATION IS NOT AN ISOLATED ONE; THAT MANY MODEL YEAR 1999-2000 5-SERIES BMWS HAVE ALSO BEEN AFFECTED. ESC MALFUNCTIONS CAN HAVE VERY NEGATIVE IMPACT ON VEHICLE SAFETY. IN JUSTIFYING THE RATIONALE FOR ITS RECENT MANDATE OF ESC, NHTSA ESTIMATES ESC WILL RED
Mileage: 72,000
WITHOUT WARNING A CRACK APPEARED IN THE RADIATOR HOUSING CAUSING A LOSS OF ANTIFREEZE. CAR WAS OUT OF WARRANTY. HAD TO REPLACE THE PART. SAME THING JUST HAPPENED AGAIN. *JB
Mileage: 45,000
Data as of 2025. Sources: NHTSA Office of Defects Investigation (ODI) complaints database, NHTSA recall campaign API, NHTSA NCAP crash-test ratings, and NHTSA FARS for fatality cross-reference.
Read our methodology — how this data is sourced, computed, and verified.