2021 BMW 540I recalls and problems

The 2021 BMW 540I has 6 recalls and 10 owner complaints on file with NHTSA; the most reported problem area is electrical system.

How the 2021 compares

Average

Fewest complaintsMost complaints

Average complaint count among 13 540I model years — 7th most.

6recalls

10complaints

1crashes

0fires

0injuries

66,700median miles

Owner complaints filed with NHTSA, not verified and not adjusted for sales. Ranking compares this model's own years only.

Does your car have an open recall?
Recalls apply to specific vehicles. Only a VIN lookup on NHTSA's official site shows whether yours is affected and still unrepaired.

Check your VIN →

6 recalls

Power Train

Aug 12, 2026 · NHTSA campaign 26V525000 · 39,144 vehicles

Problem: BMW of North America, LLC (BMW) is recalling certain 2020-2026 840i, 840i xDrive, 2021-2023 540i, 540i xDrive, M550i xDrive, and 2024-2026 750e xDrive vehicles. The connection between the driveshaft and the rear differential may become damaged, possibly resulting in a loss of power to the rear wheels or a vehicle rollaway.

Risk: An unexpected loss of drive power can increase the risk of a crash. In addition, a damaged driveshaft can result in a vehicle rollaway if the parking brake is not applied, increasing the risk of a crash or injury.

Remedy

Dealers will inspect the connection between the driveshaft and rear axle differential, and apply adhesive or replace the driveshaft and rear axle differential, as necessary, free of charge. Owner notification letters were mailed October 8, 2026. Owners may contact BMW customer service at 1-800-525-7417. Vehicle Identification Numbers (VINs) involved in this recall will become searchable on NHTSA.gov beginning October 2, 2026.

Seat Belts

Jul 21, 2021 · NHTSA campaign 21V554000 · 21,537 vehicles

Problem: BMW of North America, LLC (BMW) is recalling certain 2021 2 Series (230i, 230i xDrive, M240i, M240i xDrive), 330e, 330e Xdrive, 4 Series Coupe (430i, 430i xDrive, M440i xDrive) M4 Coupe, M4 Competition Coupe, BMW 4 Series Convertible (430i, M440i), BMW X1 sDrive28i, xDrive28i, 2 Series Gran Coupe (228i, 228i xDrive, M235i xDrive), M2 Competition Coupe, 330i, 330i xDrive, M340i, M340i xDrive, M3, M3 Competition, 530i, 530i xDrive, 540i, 540i xDrive, MINI Hardtop 2 Door (Cooper, CooperS, JCW), X2 sDrive28i, X2 xDrive28i, X2 M35i, Z4 sDrive30i, Z4 M40i, MINI Hardtop 2 Door (Cooper SE), MINI Convertible (Cooper, Cooper S, JCW), MINI Clubman (Cooper S, Cooper S All4, JCW), MINI Countryman (Cooper, Cooper All4, Cooper S, Cooper S All4, JCW All4), Rolls Royce Ghost, MINI Countryman (Cooper S E All4), Rolls Royce Phantom, Rolls Royce Cullinan, and Toyota Supra vehicles. The passenger seat belt Automatic Locking Retractor (ALR) may deactivate early, before the webbing fully retracts. As such, these assemblies fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 208, "Occupant Crash Protection."

Risk: During a crash, a seat belt retractor that does not function as intended increases the risk of injury.

Remedy & notes

Dealers will inspect the seat belt retractors (including the seat belts) and, if necessary, replace the retractors, free of charge. Owner notification letters were mailed on September 3, 2021. Owners may contact BMW customer service at 1-800-525-7417; 1-866-825-1525 (MINI); 1-877-877-3735 (Rolls Royce); and 1-888-270-9371 (Toyota).

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.nhtsa.gov.

Back Over Prevention

Feb 19, 2021 · NHTSA campaign 21V096000 · 13,858 vehicles

Problem: BMW of North America, LLC (BMW) is recalling certain 2019-2021 X3 sDrive30i, X3 xDrive30i, X3 M40i, X3M, X4 xDrive30i, X4 M40i, M550i, X4M, X5 sDrive40i, X5 xDrive40i, X5 xDrive50i, X5M, X5 M50i, X7 xDrive40i, X7 xDrive50i, X7 M50i, Alpina XB7, 330i, 330i xDrive, M340i, M340i xDrive, and 8 Series Coupe, Convertible and Grand Coupe, 840i, 840i xDrive, M850i xDrive, M8, 2020-2021 530e, 530e xDrive, 330e, 330e xDrive, 745Le, 745Le xDrive, X5 xDrive45e, X3 xDrive30e, X6 sDrive40i, X6 xDrive40i, X6 xDrive50i, X6 M50i, X6M, 530i, 530i xDrive, 540i, 540i xDrive, M550i xDrive, M5, 740i, 740Li, 740Li xDrive, M760i Drive, M760Li xDrive, 750Li xDrive Alpina, Alpina B7 xDrive, and 2021 4 Series Coupe 430i, 430i xDrive, M440i xDrive vehicles. When shifting into Reverse, a small portion of the rearview image may be obscured, or the screen may not illuminate. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 111, "Rear Visibility."

Risk: If the driver relies on only the rearview camera image, the missing or reduced rearview image view can increase the risk of a crash or injury.

Remedy & notes

BMW will notify owners, and dealers will inspect the rearview camera software and update it if necessary, free of charge. The recall began April 16, 2021. Owners may contact BMW customer service at 1-800-525-7417.

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.

Power Train

Feb 3, 2021 · NHTSA campaign 21V046000 · 28 vehicles

Problem: BMW of North America, LLC (BMW) is recalling certain 2020-2021 530i xDrive, 540i xDrive and 2021 740Li xDrive vehicles. The output shafts (left/right) which transfer power from the driveshaft to the rear wheels may break due to a heat treatment error during supplier production.

Risk: A broken output shaft can lead to a loss of drive power or a rollaway condition in a parked vehicle (if the parking brake is not engaged), increasing the risk of a crash.

Remedy & notes

BMW will notify owners, and dealers will replace the output shaft(s), free of charge. The recall began March 24, 2021. Owners may contact BMW customer service at 1-800-525-7417.

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.

Electrical System

Dec 9, 2020 · NHTSA campaign 20V761000 · 812 vehicles

Problem: BMW of North America, LLC (BMW) is recalling certain 2021 M340i xDrive, M440i xDrive Coupe, 530i, 530i xDrive, 540i, 540i xDrive, 740Li, 740Li xDrive, 840i Gran Coupe, 840i xDrive Gran Coupe, X5 sDrive40i, X5 xDrive40i, X6 sDrive40i, X6 xDrive40i, and X7 xDrive40i vehicles. The connection between the 48-Volt battery and the starter-generator may not have been assembled properly, which can cause increased electrical resistance at the connections.

Risk: Increased electrical resistance can increase the risk of a fire.

Remedy & notes

BMW will notify owners, and dealers will inspect the connection between the 48-Volt battery and the starter-generator assembly, replacing it if necessary, free of charge. The recall is expected to begin April 12, 2021. Owners may contact BMW customer service at 1-800-525-7417.

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.

Back Over Prevention

Sep 30, 2020 · NHTSA campaign 20V598000 · 312 vehicles

Problem: BMW of North America, LLC (BMW) is recalling certain 2020-2021 X3 sDrive 30i, X3 xDrive 30i, X3M 40i, X3 xDrive 30e, X4 xDrive 30i, X4M 40i, 530i, 540i, 540i xDrive, M550i xDrive, M5, 550e, 550e xDrive, and 550e iPerformance vehicles. A small portion of the rearview image may be slightly obscured. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 111, "Rear Visibility."

Risk: If the driver relies on only the rearview camera image, the reduced rearview image view can increase the risk of a crash or injury.

Remedy & notes

BMW will notify owners, and dealers will inspect and, if necessary, program the rearview camera with updated software. The recall began November 18, 2020. Owners may contact BMW customer service at 1-800-525-7417.

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.

Recall text as published by NHTSA and the manufacturer.

What owners complain about

Forward Collision Avoidance1

Seat Belts1

Steering1

Wheels1

Owner complaints filed with NHTSA; one complaint can name several areas. Not verified by NHTSA.

Complaints by year filed

NHTSA investigations

Driveshaft to rear differential connection failure

DP26009 · opened Sep 14, 2026 · closed Oct 26, 2026

Summary

The Office of Defects Investigation (ODI) received a petition on September 1, 2026 (dated August 5, 2026), requesting an investigation into an alleged defect in BMW rear differential assemblies. The petitioner alleges Model Year (MY) 2022 BMW 540i vehicles are experiencing a sudden mechanical failure that severs the drive connection between the driveshaft and the rear wheels. On August 12, 2026, BMW filed Safety Recall 26V525, which addresses the same condition raised in the petition. and covers certain 2022-2026 840i, 840i xDrive, 2021-2023 540i, 540i xDrive, M550i xDrive, and 2024-2026 750e xDrive vehicles.Â This safety recall addresses potential wear in the connection between the rear driveshaft and rear differential, which could cause the connection to fail. The Vehicle Identification Number included in the petition falls within BMWâs recall scope and subject to BMWâs reimbursement program. Because Safety Recall 26V525 fully addresses the concerns raised in the petition, further investigation is unnecessary. Therefore, ODI is denying this Defect Petition and closing this action. The agency will continue to monitor the remedy and reserves the right to take any action if warranted by future circumstances. To review the ODI reports cited in the Closing Resume ODI report Identification Number document, go to NHTSA.gov.

Pedestrian alert sounds

DP22005 · opened Jan 27, 2023 · closed Aug 7, 2023 · led to recall 22V063000

Summary

NHTSA received a petition on or about July 18, 2022, requesting that Federal Motor Vehicle Safety Standard (FMVSS) 141 be applied to all electric and hybrid vehicles operating in the United States. The petition can be reviewed at NHTSA.gov under ODI Number 11486072. FMVSS 141 establishes performance requirements for pedestrian alert sounds for motor vehicles. The standard applies to hybrid and electric vehicles that have a gross vehicle weight rating of 4,536 KG or less or are defined as low-speed vehicles. The standard became fully applicable to all such vehicles manufactured on or after March 1, 2021.On January 27, 2023, NHTSA opened Defect Petition (DP) 22-005 to evaluate the subject matter described in the petition. On June 24, 2023 and as supplemented on June 25, 2023, the petitioner notified NHTSA he was withdrawing his petition. The petitioner indicated that, based on his review of data, there is no justification for asserting potential benefits that could be derived from actions sought by my petition. Based on the petitioner's withdrawal, DP22-005 is closed. Closure of this DP does not represent a determination by NHTSA regarding the subject matter of the petition.

2021 vs. other BMW 540I years

Owner complaints by model year; the darker bar is the 2021. Click a bar to switch year.

Questions

Does the 2021 BMW 540I have recalls?

Yes — NHTSA lists 6 recall campaigns covering the 2021 BMW 540I, the latest from Aug 12, 2026 (power train). A recall applies to specific vehicles: enter your VIN at nhtsa.gov/recalls to see whether yours is affected and still open.

What are the most common problems with the 2021 BMW 540I?

Owner complaints filed with NHTSA most often mention electrical system (3), power train (3), service brakes (3). Complaints are consumer reports and are not verified by NHTSA.