Total Complaints
121 filings
BMW 545I · model year
121 NHTSA complaints, 3 crash reports for this specific cohort.
NHTSA overall rating
Not crash-tested
New Car Assessment Program
The 2005BMW545I carries 121 consumer safety complaints in NHTSA's Office of Defects Investigation database for this specific model-year cohort. Within that volume, owners reported 3 crashes, 1 fire, 1 injury, 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 2005 545I is air bags with 31 filings, followed by electrical system (14) and seat belts (9). 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 2005 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.
Total Complaints
121 filings
Crashes Reported
3 reports
Source
NHTSA ODI
Federal complaints database
At or below the fleet median complaint volume.
| Component | Count |
|---|---|
| AIR BAGS | 31 |
| ELECTRICAL SYSTEM | 14 |
| SEAT BELTS | 9 |
| POWER TRAIN | 8 |
| AIR BAGS:FRONTAL | 6 |
| STEERING | 5 |
| SERVICE BRAKES, HYDRAULIC | 5 |
| POWER TRAIN:AUTOMATIC TRANSMISSION | 5 |
| WHEELS | 4 |
| TIRES | 3 |
| ENGINE AND ENGINE COOLING | 3 |
| SEATS | 3 |
| SERVICE BRAKES | 3 |
| EXTERIOR LIGHTING | 3 |
| SERVICE BRAKES, HYDRAULIC:POWER ASSIST:VACUUM | 2 |
The contact owns a 2005 BMW 545I. The contact stated while driving at an undisclosed speed, the accelerator pedal was depressed, and the contact became aware of a ball of white smoke coming from the exhaust. The contact stated that whenever the accelerator pedal was depressed, there was white smoke coming from the exhaust pipe. The vehicle was taken to an independent mechanic where it was diagnosed with a failed crank casting and the protective crank casting valve. The contact was informed that the failure was similar to an undisclosed manufacturer's recall, however the contact's VIN was not associated with the recall. The independent mechanic informed the contact that the smoke was excessive. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 122,195.
Mileage: 122,195
The wiring inside of the headlights has dried up and fallen off, leaving bare electrical wire. The resulting was both of the headlights became non operational at night. To replace the headlights in the car with all the factory features is about 3200.00 for parts alone. I know of others who have had this happen, and everyone i know who owns one, has the same exact problem. The vehicle in question barely has 125,000 miles on it. I feel the manufacturer should repair these vehicles at no cost to the owners.
The wiring inside of the headlights has dried up and fallen off, leaving bare electrical wire. The resulting was both of the headlights became non operational at night. To replace the headlights in the car with all the factory features is about 3200.00 for parts alone. I know of others who have had this happen, and everyone i know who owns one, has the same exact problem. The vehicle in question barely has 125,000 miles on it. I feel the manufacturer should repair these vehicles at no cost to the owners.
At approxamitately 1:20pm on July 13, after being parked for a little over an hour I was told that my car was burning. 911 was called immediately and the owner of the establishment went outside and called to the firemen at the station on the other side of the street. Their response was immediate. Response was so quick that damage was limited to the right rear. Which seems that the fire started in the area directly foreward and above the battery
WHILE DRIVING TO WORK DURING MORNING RUSH HOUR IN A BUSY HIGHWAY THE CAR JUST STOPPED RUNNING. NO ODD SOUNDS NO SHUTTING NO CLUNKING. IT WAS LIKE SOME JUST TURNED THE KEY OFF. I MADE IT TO THE SIDE OF THE HIGHWAY AND HAD TO WAIT TWO HOURS FOR A TOW TRUCK TO SHOW UP. MOST OF THE WEEK PREVIOUS TO THIS MY CAR WOULD NOT START AT RANDOM TIMES EVEN THOUGH MY BATTERY WAS GOOD AND I HAD GAS. THE PROBLEM WAS THE DME HAD WATER INGRESS FROM A POOR LOCATION WHERE THE DME AND METRONIC COMPUTER AND THE INTERGRADED POWER MODULE ARE LOCATED AND STORED. THEY ARE IN A SEALED PLASTIC BOX UNDER THE CABIN FRESH AIR INLETS AND CABIN FILTERS AND THE FRONT HOOD COWL. I'M THE BOX THERE IS A FAN AT THE BOTTOM TO EXPELL MOISTER. IF THE INTERGTATED POWER MODULE STARTS TO GO THEN THE FAN STOPS WORKING OR THE FAN IT SELF GOES BAD. AT THAT POINT THERE IS ALMOST ALWAYS WATER INGRESS INTO THE DME AND OR THE METRONIC COMPUTER CAUSING THE CAR TO NOT TO RUN OR EVEN CRANK AND WITH WATER CORROSION ON THE THE DME IT CAUSE
Mileage: 127,000
DRIVING APPROXIMATELY 50 MPH AN ACCIDENT OCCURRED WHERE THERE WAS OIL IN ROAD. MY CAR LOST CONTROL AND VEERED INTO A GUARD RAIL ON THE HIGHWAY. MY CAR WAS SUBSEQUENTLY TOTALED AND NONE OF MY AIR BAGS DEPLOYED IN THE CRASH.
Mileage: 150,000
DRIVING APPROXIMATELY 50 MPH AN ACCIDENT OCCURRED WHERE THERE WAS OIL IN ROAD. MY CAR LOST CONTROL AND VEERED INTO A GUARD RAIL ON THE HIGHWAY. MY CAR WAS SUBSEQUENTLY TOTALED AND NONE OF MY AIR BAGS DEPLOYED IN THE CRASH.
Mileage: 150,000
AS I UNDERSTAND A VEHICLE FOR PASSENGER SIDE AIRBAG IN PASSENGER SIDE FREE STREAM HAS BEEN DEALT WITH ALREADY I JUST RECEIVED THIS VEHICLE SEVERAL MONTHS AGO SO IT IS NEW TO ME AND I HAVE THE SAME ERRORS AS WHICH A RECALL HAS BEEN ISSUED FOR MY CAR 2005 545 I BMW. AS I HAVE READ AFTER X AMOUNT OF YEARS A RECALL IS FINALIZED I JUST RECEIVED THIS VEHICLE SEVERAL MONTHS AGO SO I FEEL I AM STILL ABLE TO SUCCEED FROM THIS SAFETY RECALL FROM THE MANUFACTURE
Mileage: 172,000
AS I UNDERSTAND A VEHICLE FOR PASSENGER SIDE AIRBAG IN PASSENGER SIDE FREE STREAM HAS BEEN DEALT WITH ALREADY I JUST RECEIVED THIS VEHICLE SEVERAL MONTHS AGO SO IT IS NEW TO ME AND I HAVE THE SAME ERRORS AS WHICH A RECALL HAS BEEN ISSUED FOR MY CAR 2005 545 I BMW. AS I HAVE READ AFTER X AMOUNT OF YEARS A RECALL IS FINALIZED I JUST RECEIVED THIS VEHICLE SEVERAL MONTHS AGO SO I FEEL I AM STILL ABLE TO SUCCEED FROM THIS SAFETY RECALL FROM THE MANUFACTURE
Mileage: 172,000
GOOD EVENING ALL, SINCE 2011 I HAVE HAD ISSUES WITH THE I DRIVE SYSTEM. JUST RECENTLY, THE SYSTEM STOPPED WORKING. AFTER ATTEMPTING TO RESOLVE THE ISSUE WITH BMW OF ONTARIO, THEY DECLINED TO COVER THE VEHICLE'S I DRIVE COMPUTER MODULE. FINALLY, THE COMPUTER STOPPED WORKING AND I COULD NOT SEE MY COMPUTER DISPLAY OR LISTEN TO MUSIC. I COULD NOT RE-SET THE AIR PRESSURE ON THE TIRES. I DROVE THE VEHICLE THAT WAY FOR MONTHS. FINALLY, I WENT TO THE JUNK YARD AND FOUND A VEHICLE SIMILAR TO MINE AND REPLACED IT. EVEN THOUGH I REPLACED THE COMPUTER, I WAS NOT ABLE TO GAIN CERTAIN FUNCTIONS ON MY VEHICLE THAT CAME STANDARD WITH THAT PARTICULAR VEHICLE SUCH AS THE SATELLITE RADIO OR SPEAK TO CALL FUNCTION. I'M PRETTY SURE MANY VEHICLE OWNERS CAN RELATE TO THIS ISSUE AND THE DIFFICULTY IT HAS CREATED TO TRY AND MITIGATE WITH THE DEALER. TAKE CARE,
Mileage: 182,282
GOOD EVENING SIR, I AM WRITING TO YOU BECAUSE MY VEHICLE HAD BARE WIRES ON THE HEADLIGHT. THE HOT WIRE AND GROUND WIRES WERE TOUCHING. I DID NOT HAVE THE HEADLIGHT WORKING. THERE IS A PROBLEM WITH THE WIRES OF THE VEHICLE PEELING OFF AFTER A CERTAIN AMOUNT OF TIME.
GOOD EVENING ALL, EVERY TIME I FILL UP THE GAS IN THE VEHICLE, THERE IS A STRONG SMELL INSIDE THE CAB. THIS BEGAN OCCURRING ABOUT 4 YEARS AGO BUT HAS CONTINUED THOUGHT MY TIME WITH THE VEHICLE. CURRENTLY, I CANNOT FILL THE TANK AT MORE THAN . IF I DO FILL UP THE VEHICLE TO MORE THAN I FACE HAVING TO SMELL THE FUMES OF THE FUEL INSIDE THE CAB OF THE VEHICLE. THIS IS A SAFETY ISSUE AND SHOULD BE RECALLED. MANY PEOPLE HAVE A SIMILAR COMPLAINT WITH THESE VEHICLES.
Mileage: 182,252
CERTAIN BMW MODELS INCLUDING E60 2005 545I ALMOST ALL REQUIRE VALVE SEAL REPLACEMENT DUE TO FAULTY MANUFACTURING DEFECTS. THIS RESULTS IN OIL LEAKING INTO THE ENGINE AND SECONDARY AIR INJECTOR CAUSING SMOKE TO EMIT OUT OF THE TAILPIPES. ALTHOUGH MY CAR PASSED AL COMPUTERIZED SMOG CHECKS, IT DID NOT PASS THE NEW VISUAL TEST BECAUSE OF THESE FAULTY VALVE STEM SEALS. THIS OCCURS AFTE IDLING THE ENGINE FOR 10 MINUTES. THE REPAIR COSTS FOR THIS ARE ABOUT EQUAL TO THE RETAIL VALUE OF THE CAR. EVERY MECHANIC I'VE SPOKEN TO BELIEVES THIS SHOULD BE RECALLED.
Mileage: 160,000
TL* THE CONTACT OWNS A 2005 BMW 545I. WHILE THE SEAT HEATER WAS ACTIVATED, THE FRONT DRIVER'S SEAT BECAME EXTREMELY HOT. SMOKE WAS SEEN COMING FROM THE SEAT AND THE RIGHT SIDE OF THE STEERING WHEEL. THE SEAT HEATER WAS TURNED OFF AND THERE WERE NO WARNING INDICATORS ILLUMINATED. THE CONTACT WAS CONCERNED THAT THIS COULD CAUSE A FIRE. THE VEHICLE WAS TAKEN TO HABBERSTAD BMW NEW AND PRE-OWNED (945 E JERICHO TURNPIKE, HUNTINGTON STATION, NY 11746 (800) 997-9313) WHERE IT WAS DIAGNOSED THAT THE FAULTY HEATER WIRING, THE SEAT, AND THE STEERING WHEEL NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND STATED THAT THE VEHICLE WAS NOT COVERED UNDER WARRANTY. THE CONTACT WAS ADVISED NOT TO ACTIVATE THE SEAT HEATER. THE FAILURE MILEAGE WAS 123,000. UPDATED 08/30/17*LJ *TR
Mileage: 123,000
TL* THE CONTACT OWNS A 2005 BMW 545I. WHILE THE SEAT HEATER WAS ACTIVATED, THE FRONT DRIVER'S SEAT BECAME EXTREMELY HOT. SMOKE WAS SEEN COMING FROM THE SEAT AND THE RIGHT SIDE OF THE STEERING WHEEL. THE SEAT HEATER WAS TURNED OFF AND THERE WERE NO WARNING INDICATORS ILLUMINATED. THE CONTACT WAS CONCERNED THAT THIS COULD CAUSE A FIRE. THE VEHICLE WAS TAKEN TO HABBERSTAD BMW NEW AND PRE-OWNED (945 E JERICHO TURNPIKE, HUNTINGTON STATION, NY 11746 (800) 997-9313) WHERE IT WAS DIAGNOSED THAT THE FAULTY HEATER WIRING, THE SEAT, AND THE STEERING WHEEL NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND STATED THAT THE VEHICLE WAS NOT COVERED UNDER WARRANTY. THE CONTACT WAS ADVISED NOT TO ACTIVATE THE SEAT HEATER. THE FAILURE MILEAGE WAS 123,000. UPDATED 08/30/17*LJ *TR
Mileage: 123,000
I AM WRITING TO YOU TO ADDRESS A CURRENT NATIONAL HIGHWAY TRAFFIC ADMINISTRATION (NHTSA) SAFETY RECALL AFFECTING MY VEHICLE (AND PRESUMABLY MANY SIMILAR VEHICLES). I CURRENTLY OWN A 2005 BMW 545I 4-DOOR SEDAN (VIN: [XXX] WITH 84,474 MILES AND HAVE RECENTLY EXPERIENCED A FRONT PASSENGER SEAT OCCUPANT DETECTION MAT MALFUNCTION. THIS SENSOR MALFUNCTION AFFECTS THE DEPLOYMENT OF THE FRONT PASSENGER SEAT AIRBAG IN THE EVENT OF A COLLISION. THE ERROR CODES MY VEHICLE IS DISPLAYING ARE THE SAME AS THOSE ADDRESSED IN THE NHTSA SAFETY RECALL (NHTSA CAMPAIGN NUMBER 08V384000, DATED 5 AUG 2008) INDICATING A PASSENGER AIRBAG HAS MALFUNCTIONED, "OFF", AND WILL NOT DEPLOY IN THE EVENT OF AN EMERGENCY. THE NHTSA RECALL INDICATED BMW IS RECALLING 2004-06 5-SERIES MODELS (INCLUDING THE 545I) EQUIPPED WITH SEAT TYPES THAT MAY PRODUCE SIMILAR ERRORS DUE TO CRACKING THAT DEVELOPS WITH AGE. FRANKLY, I FIND IT RIDICULOUS THAT OTHER VEHICLES WITH THE SAME YEAR, MAKE, AND MODEL ARE EXPERIENCING THE SAME MALFU
Mileage: 84,474
I AM WRITING TO YOU TO ADDRESS A CURRENT NATIONAL HIGHWAY TRAFFIC ADMINISTRATION (NHTSA) SAFETY RECALL AFFECTING MY VEHICLE (AND PRESUMABLY MANY SIMILAR VEHICLES). I CURRENTLY OWN A 2005 BMW 545I 4-DOOR SEDAN (VIN: [XXX] WITH 84,474 MILES AND HAVE RECENTLY EXPERIENCED A FRONT PASSENGER SEAT OCCUPANT DETECTION MAT MALFUNCTION. THIS SENSOR MALFUNCTION AFFECTS THE DEPLOYMENT OF THE FRONT PASSENGER SEAT AIRBAG IN THE EVENT OF A COLLISION. THE ERROR CODES MY VEHICLE IS DISPLAYING ARE THE SAME AS THOSE ADDRESSED IN THE NHTSA SAFETY RECALL (NHTSA CAMPAIGN NUMBER 08V384000, DATED 5 AUG 2008) INDICATING A PASSENGER AIRBAG HAS MALFUNCTIONED, "OFF", AND WILL NOT DEPLOY IN THE EVENT OF AN EMERGENCY. THE NHTSA RECALL INDICATED BMW IS RECALLING 2004-06 5-SERIES MODELS (INCLUDING THE 545I) EQUIPPED WITH SEAT TYPES THAT MAY PRODUCE SIMILAR ERRORS DUE TO CRACKING THAT DEVELOPS WITH AGE. FRANKLY, I FIND IT RIDICULOUS THAT OTHER VEHICLES WITH THE SAME YEAR, MAKE, AND MODEL ARE EXPERIENCING THE SAME MALFU
Mileage: 84,474
HELLO SIR OR MA'AM; I AM WRITING TO YOU TO ADDRESS A CURRENT NATIONAL HIGHWAY TRAFFIC ADMINISTRATION (NHTSA) SAFETY RECALL AFFECTING MY VEHICLE (AND PRESUMABLY MANY SIMILAR VEHICLES). I CURRENTLY OWN A 2005 BMW 545I 4-DOOR SEDAN (VIN: [XXX]) AND HAVE RECENTLY EXPERIENCED A FRONT PASSENGER SEAT OCCUPANT DETECTION MAT MALFUNCTION. THIS SENSOR MALFUNCTION AFFECTS THE DEPLOYMENT OF THE FRONT PASSENGER SEAT AIRBAG IN THE EVENT OF A COLLISION. THE ERROR CODES MY VEHICLE IS DISPLAYING ARE THE SAME AS THOSE ADDRESSED IN THE NHTSA SAFETY RECALL (NHTSA CAMPAIGN NUMBER 08V384000, DATED 5 AUG 2008) INDICATING A PASSENGER AIRBAG HAS MALFUNCTIONED, "OFF", AND WILL NOT DEPLOY IN THE EVENT OF AN EMERGENCY. THE NHTSA RECALL INDICATED BMW IS RECALLING 2004-06 5-SERIES MODELS (INCLUDING THE 545I) EQUIPPED WITH SEAT TYPES THAT MAY PRODUCE SIMILAR ERRORS DUE TO CRACKING THAT DEVELOPS WITH AGE. FRANKLY, I FIND IT RIDICULOUS THAT OTHER VEHICLES WITH THE SAME YEAR, MAKE, AND MODEL ARE EXPERIENCING T
MY PASSENGER SIDE AIR BAG LIGHT AND SEAT BELT LIGHT ARE BOTH ON AT ALL TIMES. THE ON BOARD COMPUTER SAYS FAULT IN PASSENGER SIDE SEAT BELT OR SEAT BELT TENSIONER. ALSO THE BACK BRAKES DON'T WORK AT ALL BUT THE FRONT ONES DO. WAS WONDERING IF THIS WAS A RECALL MATTER BEFORE I SPEND THOUSANDS TO FIX THE PROBLEM
MY PASSENGER SIDE AIR BAG LIGHT AND SEAT BELT LIGHT ARE BOTH ON AT ALL TIMES. THE ON BOARD COMPUTER SAYS FAULT IN PASSENGER SIDE SEAT BELT OR SEAT BELT TENSIONER. ALSO THE BACK BRAKES DON'T WORK AT ALL BUT THE FRONT ONES DO. WAS WONDERING IF THIS WAS A RECALL MATTER BEFORE I SPEND THOUSANDS TO FIX THE PROBLEM
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.