BMW 545I · model year

2004 BMW 545I

77 NHTSA complaints, 1 crash report for this specific cohort.

NHTSA overall rating

Not crash-tested

New Car Assessment Program

The 2004BMW545I carries 77 consumer safety complaints in NHTSA's Office of Defects Investigation database for this specific model-year cohort. Within that volume, owners reported 1 crash, 2 fires, 5 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 2004 545I is air bags with 18 filings, followed by electrical system (12) and engine (10). 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 2004 545I. 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.

77
Complaints
1
Crashes
2
Fires
5
Injuries
0
Deaths

Total Complaints

77 filings

Crashes Reported

1 reports

Source

NHTSA ODI

Federal complaints database

Complaints vs. fleet median (215)

At or below the fleet median complaint volume.

Complaints by Component

ComponentCount
AIR BAGS18
ELECTRICAL SYSTEM12
ENGINE10
POWER TRAIN8
SEAT BELTS5
STEERING4
ELECTRONIC STABILITY CONTROL (ESC)4
SERVICE BRAKES3
SEATS3
EXTERIOR LIGHTING3
SERVICE BRAKES, HYDRAULIC2
ENGINE AND ENGINE COOLING2
VEHICLE SPEED CONTROL1
UNKNOWN OR OTHER1
AIR BAGS:SENSOR:OCCUPANT CLASSIFICATION1

Recent Complaints

20200204AIR BAGS

MY CAR HAS THE PASSENGER RESTRAINT SYSTEM WARNING EVERYTIME I START MY CAR. THE AIR BAG RECALL IS BY TAKATA IS FOR THE 2003 545I MODEL. MY CAR WAS MANUFACTURED IN SEP OF 2003 WITH THOSE TAKADA AIRBAGS.

20200204SEAT BELTS

MY CAR HAS THE PASSENGER RESTRAINT SYSTEM WARNING EVERYTIME I START MY CAR. THE AIR BAG RECALL IS BY TAKATA IS FOR THE 2003 545I MODEL. MY CAR WAS MANUFACTURED IN SEP OF 2003 WITH THOSE TAKADA AIRBAGS.

20200119ELECTRONIC STABILITY CONTROL (ESC)

DYNAMIC STEERING MALFUNCTION CAUSING HAZARDOUS DRIVING CONDITIONS AT HIGHWAY SPEEDS

Mileage: 130,000

20200119STEERING

DYNAMIC STEERING MALFUNCTION CAUSING HAZARDOUS DRIVING CONDITIONS AT HIGHWAY SPEEDS

Mileage: 130,000

20191128ELECTRICAL SYSTEM

ELECTRICAL WIRING IN HEADLIGHTS ARE DISINTEGRATING. THE SHIELDING IS DRY ROTTING AND FLAKING OFF NEARLY EVERY WIRE IN BOTH HEADLIGHTS CAUSING THEM TO MALFUNCTION DURING DRIVING. LIGHTS WILL CUT OFF RANDOMLY. I'D IMAGINE THE WIRES ARE SHORTING OUT.

Mileage: 180,000

20191128EXTERIOR LIGHTING

ELECTRICAL WIRING IN HEADLIGHTS ARE DISINTEGRATING. THE SHIELDING IS DRY ROTTING AND FLAKING OFF NEARLY EVERY WIRE IN BOTH HEADLIGHTS CAUSING THEM TO MALFUNCTION DURING DRIVING. LIGHTS WILL CUT OFF RANDOMLY. I'D IMAGINE THE WIRES ARE SHORTING OUT.

Mileage: 180,000

20190908ENGINE

VALVE COVER GASKET LEAK, TIMING CHAIN COVER GASKET LEAK, VALVE STEM LEAK.

Mileage: 97,000

20190207ELECTRICAL SYSTEM

BARE WIRES INSIDE THE HEADLIGHT HOUSING, THESE ARE HID LIGHTS MADE BY HELLA FOR BMW THEY ARE OEM. WHEN CONTACTING BMWNA THEY SAY THAT'S NOT HOW THEY MAKE THERE LIGHTS AND BLAME HEAT AND THE CAR NOT BEING MAINTAINED AT A BMW DEALERSHIP, WELL THE REST OF THE WIRING ON THE CAR IS JUST FINE EVEN THE WIRES THAT COME IN CONTACT WITH A HIGH HEAT PRODUCING ENGINE... IT'S THE SAME EXACT ISSUE MERCEDES BENZ HAD ON THE W202 CHASSIS, WIRES THAT WOULD DEGRADE AT AN EXTREMELY FAST RATE. BUT FOR HEADLIGHTS THAT COST WELL OVER $1000 EACH. BUT MY QUESTION IS WHAT HAPPENS WHEN A FAMILY IS OUT AT NIGHT AND THERE HEADLIGHTS MALFUNCTION BECAUSE OF SOMETHING BMW KNOWS ABOUT BUT REFUSE TO TAKE RESPONSIBILITY AND SAID FAMILY HAS A WRECK AND KILLS MULTIPLE PEOPLE BECAUSE OF A KNOWN PROBLEM. THIS IS MY SECOND ATTEMPT AT GETTING SOMETHING DONE THE FIRST WAS CONTACTING BMWNA WHICH EQUALED TO INSULTING SOMEONE'S KNOWLEDGE OF ELECTRICAL COMPONENTS. ALSO THE HEADLIGHTS NO LONGER ADJUST, THE ANGEL EYES NO LONGER WORK

Mileage: 119,000

20190207EXTERIOR LIGHTING

BARE WIRES INSIDE THE HEADLIGHT HOUSING, THESE ARE HID LIGHTS MADE BY HELLA FOR BMW THEY ARE OEM. WHEN CONTACTING BMWNA THEY SAY THAT'S NOT HOW THEY MAKE THERE LIGHTS AND BLAME HEAT AND THE CAR NOT BEING MAINTAINED AT A BMW DEALERSHIP, WELL THE REST OF THE WIRING ON THE CAR IS JUST FINE EVEN THE WIRES THAT COME IN CONTACT WITH A HIGH HEAT PRODUCING ENGINE... IT'S THE SAME EXACT ISSUE MERCEDES BENZ HAD ON THE W202 CHASSIS, WIRES THAT WOULD DEGRADE AT AN EXTREMELY FAST RATE. BUT FOR HEADLIGHTS THAT COST WELL OVER $1000 EACH. BUT MY QUESTION IS WHAT HAPPENS WHEN A FAMILY IS OUT AT NIGHT AND THERE HEADLIGHTS MALFUNCTION BECAUSE OF SOMETHING BMW KNOWS ABOUT BUT REFUSE TO TAKE RESPONSIBILITY AND SAID FAMILY HAS A WRECK AND KILLS MULTIPLE PEOPLE BECAUSE OF A KNOWN PROBLEM. THIS IS MY SECOND ATTEMPT AT GETTING SOMETHING DONE THE FIRST WAS CONTACTING BMWNA WHICH EQUALED TO INSULTING SOMEONE'S KNOWLEDGE OF ELECTRICAL COMPONENTS. ALSO THE HEADLIGHTS NO LONGER ADJUST, THE ANGEL EYES NO LONGER WORK

Mileage: 119,000

20180607AIR BAGS:SENSOR:OCCUPANT CLASSIFICATION

IN 10/17 I BOUGHT THE ABOVE VEHICLE FROM PRIVATE OWNER. FROM THE TIME I STARTED DRIVING IT TO CURRENTLY, THE CONTROL DISPLAY HAS BEEN SHOWING A PASSENGER AIRBAG AND/ORSEATBEIT WARNING. THE CURRENT WARNING READS: "PASS. RESTRAINT SYSTEM. FAULT IN PASSENGER-RESTRIANT SYSTEM AFFECTING AIRBAG, BELT TENSIONER OR BELT FORCE LIMITER." THE DISPLAY BETWEEN THE SPEEDOMETER AND TACHOMETER SHOWS A RED AIRBAG SYMBOL AND A RED FASTEN SEATBELT SYMBOL, WHICH DO NOT GO OFF WITH OPERATION OF VEHICLE. THESE 2004/2005 BMW 545I HAD A NHTSA SAFETY RECALL (08V384000) BUT CERTAIN VINS, INCLUDING MINE WERE NOT INCLUDED. I CANNOT UNDERSTAND WHY, BECAUSE CLEARLY NOT KNOWING WHETHER YOUR AIRBAG & BELT TENSIONER & BELT FORCE LIMITER ARE WORKING PROPERLY IS A SAFETY ISSUE. I AM NOT THE ONLY ONE WITH THIS CONCERN, PLEASE SEE AT LEAST 10 OTHER PEOPLE LISTING THIS PROBLEM WITH "WWW.CARPROBLEMZOO.COM" UNDER BMW 545 I SEATBELT PROBLEMS. MY MECHANIC HAS TRIED SEVERAL TIMES TO RESET THESE WARNINGS, BUT THEY ALWAY

20180607AIR BAGS

IN 10/17 I BOUGHT THE ABOVE VEHICLE FROM PRIVATE OWNER. FROM THE TIME I STARTED DRIVING IT TO CURRENTLY, THE CONTROL DISPLAY HAS BEEN SHOWING A PASSENGER AIRBAG AND/ORSEATBEIT WARNING. THE CURRENT WARNING READS: "PASS. RESTRAINT SYSTEM. FAULT IN PASSENGER-RESTRIANT SYSTEM AFFECTING AIRBAG, BELT TENSIONER OR BELT FORCE LIMITER." THE DISPLAY BETWEEN THE SPEEDOMETER AND TACHOMETER SHOWS A RED AIRBAG SYMBOL AND A RED FASTEN SEATBELT SYMBOL, WHICH DO NOT GO OFF WITH OPERATION OF VEHICLE. THESE 2004/2005 BMW 545I HAD A NHTSA SAFETY RECALL (08V384000) BUT CERTAIN VINS, INCLUDING MINE WERE NOT INCLUDED. I CANNOT UNDERSTAND WHY, BECAUSE CLEARLY NOT KNOWING WHETHER YOUR AIRBAG & BELT TENSIONER & BELT FORCE LIMITER ARE WORKING PROPERLY IS A SAFETY ISSUE. I AM NOT THE ONLY ONE WITH THIS CONCERN, PLEASE SEE AT LEAST 10 OTHER PEOPLE LISTING THIS PROBLEM WITH "WWW.CARPROBLEMZOO.COM" UNDER BMW 545 I SEATBELT PROBLEMS. MY MECHANIC HAS TRIED SEVERAL TIMES TO RESET THESE WARNINGS, BUT THEY ALWAY

20180607SEAT BELTS

IN 10/17 I BOUGHT THE ABOVE VEHICLE FROM PRIVATE OWNER. FROM THE TIME I STARTED DRIVING IT TO CURRENTLY, THE CONTROL DISPLAY HAS BEEN SHOWING A PASSENGER AIRBAG AND/ORSEATBEIT WARNING. THE CURRENT WARNING READS: "PASS. RESTRAINT SYSTEM. FAULT IN PASSENGER-RESTRIANT SYSTEM AFFECTING AIRBAG, BELT TENSIONER OR BELT FORCE LIMITER." THE DISPLAY BETWEEN THE SPEEDOMETER AND TACHOMETER SHOWS A RED AIRBAG SYMBOL AND A RED FASTEN SEATBELT SYMBOL, WHICH DO NOT GO OFF WITH OPERATION OF VEHICLE. THESE 2004/2005 BMW 545I HAD A NHTSA SAFETY RECALL (08V384000) BUT CERTAIN VINS, INCLUDING MINE WERE NOT INCLUDED. I CANNOT UNDERSTAND WHY, BECAUSE CLEARLY NOT KNOWING WHETHER YOUR AIRBAG & BELT TENSIONER & BELT FORCE LIMITER ARE WORKING PROPERLY IS A SAFETY ISSUE. I AM NOT THE ONLY ONE WITH THIS CONCERN, PLEASE SEE AT LEAST 10 OTHER PEOPLE LISTING THIS PROBLEM WITH "WWW.CARPROBLEMZOO.COM" UNDER BMW 545 I SEATBELT PROBLEMS. MY MECHANIC HAS TRIED SEVERAL TIMES TO RESET THESE WARNINGS, BUT THEY ALWAY

20180519AIR BAGS

SAME PROBLEM EVERYONE ELSE HAS WITH PASSENGER SIDE AIR BAG MALFUNCTION. $1500+ REPAIR, BUT WILL DO IT AGAIN, AS IT IS FAULTY PARTS. SOMEONE SITS DOWN IN THE PASSENGER SEAT TOO HARD, AND IT SETS OFF THE WARNING.

Mileage: 190,000

20170824AIR BAGS

TAKADA RECALL. MY CAR'S MAKE CRACKING NOISE OR GROANED NOISES AS SOME OTHER E60 OWNERS DESCRIBED. THE NOISES SOUNDED AS THE CAR START ROLLING AT LOW SPEED WHETHER GO STRAIGHT OR TURN A LITTLE TO LEFT OR RIGHT. IT'S HAPPENED EVERY TIME. THE AIRBAG LIGHT COME ON DURING DRIVE AND IT IS OFF WHEN I SHUT OFF THE ENGINE. THE NEXT TIME I START THE CAR IS STILL REMAIN STAYED ON, AND IT'S GOES OFF DURING DRIVE. THE STEERING WHEEL SEEMS NOT FIRM UNLIKE E39 IS MORE FIRM. I FOUND A FORUM WHERE THE E60 OWNERS HAD SIMILAR PROBLEM AND THE DEALER SOLVED THE PROBLEMS I MENTIONED ABOVE BY JUST REPLACE THE TAKATA AIRBAG AND MAYBE AN UPDATE OF SOFTWARE INVOLVED. IN CONCLUSION TO MY COMPLAINT REGARDING TAKADA AIRBAG THE BMW SHOULD OPEN A RECALL FOR MY CAR OR ADD MY CAR TO THE RECALL LIST AS IT'S NOT SAFE FOR ME AND MY FAMILY. PLEASE HELP, THANK YOU.

Mileage: 15,000

20170824ELECTRONIC STABILITY CONTROL (ESC)

TAKADA RECALL. MY CAR'S MAKE CRACKING NOISE OR GROANED NOISES AS SOME OTHER E60 OWNERS DESCRIBED. THE NOISES SOUNDED AS THE CAR START ROLLING AT LOW SPEED WHETHER GO STRAIGHT OR TURN A LITTLE TO LEFT OR RIGHT. IT'S HAPPENED EVERY TIME. THE AIRBAG LIGHT COME ON DURING DRIVE AND IT IS OFF WHEN I SHUT OFF THE ENGINE. THE NEXT TIME I START THE CAR IS STILL REMAIN STAYED ON, AND IT'S GOES OFF DURING DRIVE. THE STEERING WHEEL SEEMS NOT FIRM UNLIKE E39 IS MORE FIRM. I FOUND A FORUM WHERE THE E60 OWNERS HAD SIMILAR PROBLEM AND THE DEALER SOLVED THE PROBLEMS I MENTIONED ABOVE BY JUST REPLACE THE TAKATA AIRBAG AND MAYBE AN UPDATE OF SOFTWARE INVOLVED. IN CONCLUSION TO MY COMPLAINT REGARDING TAKADA AIRBAG THE BMW SHOULD OPEN A RECALL FOR MY CAR OR ADD MY CAR TO THE RECALL LIST AS IT'S NOT SAFE FOR ME AND MY FAMILY. PLEASE HELP, THANK YOU.

Mileage: 15,000

20170824STEERING

TAKADA RECALL. MY CAR'S MAKE CRACKING NOISE OR GROANED NOISES AS SOME OTHER E60 OWNERS DESCRIBED. THE NOISES SOUNDED AS THE CAR START ROLLING AT LOW SPEED WHETHER GO STRAIGHT OR TURN A LITTLE TO LEFT OR RIGHT. IT'S HAPPENED EVERY TIME. THE AIRBAG LIGHT COME ON DURING DRIVE AND IT IS OFF WHEN I SHUT OFF THE ENGINE. THE NEXT TIME I START THE CAR IS STILL REMAIN STAYED ON, AND IT'S GOES OFF DURING DRIVE. THE STEERING WHEEL SEEMS NOT FIRM UNLIKE E39 IS MORE FIRM. I FOUND A FORUM WHERE THE E60 OWNERS HAD SIMILAR PROBLEM AND THE DEALER SOLVED THE PROBLEMS I MENTIONED ABOVE BY JUST REPLACE THE TAKATA AIRBAG AND MAYBE AN UPDATE OF SOFTWARE INVOLVED. IN CONCLUSION TO MY COMPLAINT REGARDING TAKADA AIRBAG THE BMW SHOULD OPEN A RECALL FOR MY CAR OR ADD MY CAR TO THE RECALL LIST AS IT'S NOT SAFE FOR ME AND MY FAMILY. PLEASE HELP, THANK YOU.

Mileage: 15,000

20170821ELECTRICAL SYSTEM

MY I DRIVE OR CCC HAS MALFUNCTIONED. AT FIRST THE SCREEN WOULD TURN ON AND OFF OR FREEZE UP. FINALLY THE SCREEN WENT BLANK. THIS UNIT PROVIDE THE SAFETY INFORMATION OF THE VEHICLE. THIS UNIT ALSO PROVIDES THE COMMUNICATIONS SUCH AS BLUETOOTH AND HANDS FREE FUNCTIONS. THIS UNIT ALSO PROVIDES ALL THE SERVICE INFORMATION/ BASICALLY IT LIKE DRIVING A VEHICLE WITH OUT A BRAIN. THIS SEEMS TO BE A RECURRING PROBLEM WITH OTHER BMW OWNER.

Mileage: 174,250

20170810ELECTRONIC STABILITY CONTROL (ESC)

I CAME BACK FROM MY SUMMER HOLIDAY, AND RESTARTED MY CAR. A LOT OF WARNINGS APPEARS ON THE ODOMETER. ABOUT ENGINE, AIRBAGS, STEERING, TIRE PRESSURE, AND SEAT BELT. (I HAVE CHECKED THE TIRE PRESSURE, IT IS NORMAL. AND I ALWAYS LOCK THE SEAT BELT BEFORE DRIVING). IN ADDITION, THE NAVIGATION SCREEN AND RADIO DIED. FURTHERMORE, THE CAR LOSE ELECTRICITY AFTER IT SHUTS DOWN. AFTER MORE THAN 3 HOURS OF SHUT DOWN, IT WON'T HAVE ENOUGH POWER TO RE-IGNITE. I CHECK ON NHTSA WEBSITE THAT THERE ARE THREE RECALL ISSUES THAT MY CAR WAS INCLUDED, AND RELATED TO THE ISSUES I AM REPORTING RIGHT NOW. ABOUT AIR BAGS (08V384000), ENGINE (12E029000), AND ELECTRICAL SYSTEM (12V126000). BUT I CANNOT FIND OUT ANY INFORMATION BY MY VIN NUMBER ON NHTSA. IT IS A USED CAR, I AM NOT SURE WHETHER THE FORMER USER RESPONDED THE RECALL BEFORE. EVEN IF THIS CAR WAS RECALLED BEFORE, I DON'T KNOW WHETHER IT WAS FIXED PROPERLY, AND THE SIMILAR ISSUES WOULD NOT HAPPEN AGAIN.

Mileage: 106,590

20170810ENGINE AND ENGINE COOLING

I CAME BACK FROM MY SUMMER HOLIDAY, AND RESTARTED MY CAR. A LOT OF WARNINGS APPEARS ON THE ODOMETER. ABOUT ENGINE, AIRBAGS, STEERING, TIRE PRESSURE, AND SEAT BELT. (I HAVE CHECKED THE TIRE PRESSURE, IT IS NORMAL. AND I ALWAYS LOCK THE SEAT BELT BEFORE DRIVING). IN ADDITION, THE NAVIGATION SCREEN AND RADIO DIED. FURTHERMORE, THE CAR LOSE ELECTRICITY AFTER IT SHUTS DOWN. AFTER MORE THAN 3 HOURS OF SHUT DOWN, IT WON'T HAVE ENOUGH POWER TO RE-IGNITE. I CHECK ON NHTSA WEBSITE THAT THERE ARE THREE RECALL ISSUES THAT MY CAR WAS INCLUDED, AND RELATED TO THE ISSUES I AM REPORTING RIGHT NOW. ABOUT AIR BAGS (08V384000), ENGINE (12E029000), AND ELECTRICAL SYSTEM (12V126000). BUT I CANNOT FIND OUT ANY INFORMATION BY MY VIN NUMBER ON NHTSA. IT IS A USED CAR, I AM NOT SURE WHETHER THE FORMER USER RESPONDED THE RECALL BEFORE. EVEN IF THIS CAR WAS RECALLED BEFORE, I DON'T KNOW WHETHER IT WAS FIXED PROPERLY, AND THE SIMILAR ISSUES WOULD NOT HAPPEN AGAIN.

Mileage: 106,590

20170810AIR BAGS

I CAME BACK FROM MY SUMMER HOLIDAY, AND RESTARTED MY CAR. A LOT OF WARNINGS APPEARS ON THE ODOMETER. ABOUT ENGINE, AIRBAGS, STEERING, TIRE PRESSURE, AND SEAT BELT. (I HAVE CHECKED THE TIRE PRESSURE, IT IS NORMAL. AND I ALWAYS LOCK THE SEAT BELT BEFORE DRIVING). IN ADDITION, THE NAVIGATION SCREEN AND RADIO DIED. FURTHERMORE, THE CAR LOSE ELECTRICITY AFTER IT SHUTS DOWN. AFTER MORE THAN 3 HOURS OF SHUT DOWN, IT WON'T HAVE ENOUGH POWER TO RE-IGNITE. I CHECK ON NHTSA WEBSITE THAT THERE ARE THREE RECALL ISSUES THAT MY CAR WAS INCLUDED, AND RELATED TO THE ISSUES I AM REPORTING RIGHT NOW. ABOUT AIR BAGS (08V384000), ENGINE (12E029000), AND ELECTRICAL SYSTEM (12V126000). BUT I CANNOT FIND OUT ANY INFORMATION BY MY VIN NUMBER ON NHTSA. IT IS A USED CAR, I AM NOT SURE WHETHER THE FORMER USER RESPONDED THE RECALL BEFORE. EVEN IF THIS CAR WAS RECALLED BEFORE, I DON'T KNOW WHETHER IT WAS FIXED PROPERLY, AND THE SIMILAR ISSUES WOULD NOT HAPPEN AGAIN.

Mileage: 106,590

Compare 2004BMW545I to Similar Vehicles

NHTSA Investigations

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Frequently Asked Questions

How many complaints does the 2004 BMW 545I have?
The 2004 BMW 545I has 77 NHTSA complaints, 1 crashes, 2 fires, 5 injuries, and 0 deaths reported.
What are the most common problems with the 2004 BMW 545I?
The most-complained component for the 2004 BMW 545I is AIR BAGS with 18 complaints. Other frequently reported areas include ELECTRICAL SYSTEM and ENGINE.
Is the 2004 BMW 545I safe to buy?
Review the complaint history, crash and fire reports, safety ratings, and recall status on this page to make an informed decision. No NHTSA crash test rating is available for this model year. Compare with other model years using the links above.
Where does this data come from?
All complaint, recall, and safety rating data is sourced from the National Highway Traffic Safety Administration (NHTSA). Complaints are filed by vehicle owners through NHTSA's Office of Defects Investigation.

Vehicle Safety Guides

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.