Owners have filed 13 complaints
about the 2021 BMW 540I with NHTSA between 2022 and 2026.
The largest single group is the brakes.
Across this model's run it ranks 5 of 13 worst.
The letter says how bad. This says what kind — whether this year drew
an unusual number of complaints, unusually dangerous
ones, or failures that arrived unusually early.
The dashed ring is 50 — the national norm. Further out is worse.
Complaint volume — 27
Against the median year of the BMW 540I. 50 means typical for this
model; 100 means roughly double.
Severity — 100
23.1% of these complaints
involved a crash, fire, injury or death, against a national rate of
9.7%.
Early failure — not reported
Too few complaints recorded a mileage to measure this.
Complaints filed with NHTSA, by model year. Bar colour is the FaultScore grade:
A
B
C
D
F
ungraded
What breaks on a 2021 BMW 540I
Every complaint is filed against a part. Follow any row for the complaints about that part alone.
Brakes
323.1%
1 crashes, 0 fires
Driver Assist & Collision Avoidance
215.4%
2 crashes, 0 fires
Electrical System
215.4%
Transmission & Drivetrain
215.4%
Median failure at 66,700 miles
Seat Belts
17.7%
Median failure at 10,000 miles
Wheels
17.7%
Steering
17.7%
Engine & Cooling
17.7%
When owners complained
A spike years after the car went on sale usually means a part wearing
out on schedule across the whole fleet — the kind of pattern no single
owner can see from inside their own car.
Jan 2022peak 3Jul 2026
NHTSA investigations into the 2021 BMW 540I
An investigation is the step before a recall: the agency has seen enough
complaints to look into a pattern itself. An open one means it thinks
something may be wrong and nothing has been fixed yet.
DP22005Opened 27 Jan 2023Closed 7 Aug 2023ELECTRICAL SYSTEM:PROPULSION SYSTEM
Pedestrian alert sounds
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 Marc...
Complaints that involved harm
Reports where the owner recorded a crash, a fire, an injury or a death.
Edina, MNCrash
SERVICE BRAKES
Unintended car acceleration, with complete brake failure. No software warning icons in dash, no collision avoidance or ABS triggered even though car so equipped. Crashed into rear end of stationery vehicle,. [XXX] , MN police were called. Incident report # attached. (1st image) Western National Insurance Co. notified.Claim # attached (2nd image) Car will be inspected @ BMW dealership in Bloomington, MN 7/25/23. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA complaint #11533979 — an unverified report by a vehicle owner.
Edina, MNCrash
FORWARD COLLISION AVOIDANCE: WARNINGS
Unintended car acceleration, with complete brake failure. No software warning icons in dash, no collision avoidance or ABS triggered even though car so equipped. Crashed into rear end of stationery vehicle,. [XXX] , MN police were called. Incident report # attached. (1st image) Western National Insurance Co. notified.Claim # attached (2nd image) Car will be inspected @ BMW dealership in Bloomington, MN 7/25/23. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA complaint #11533979 — an unverified report by a vehicle owner.
Unintended car acceleration, with complete brake failure. No software warning icons in dash, no collision avoidance or ABS triggered even though car so equipped. Crashed into rear end of stationery vehicle,. [XXX] , MN police were called. Incident report # attached. (1st image) Western National Insurance Co. notified.Claim # attached (2nd image) Car will be inspected @ BMW dealership in Bloomington, MN 7/25/23. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA complaint #11533979 — an unverified report by a vehicle owner.
The most recent complaints
In the owners' own words, exactly as filed with NHTSA.
Upper Marlboro, MD
POWER TRAIN
Starter engine failure. Car failed to start multiple times. Major safety hazard that can cause a short circuit, melt wiring harnesses, and spark an engine bay fire posing an immediate threat to life. Problem was inspected and confirmed by a dealer. Multiple waring lamps and messages appeared. Dealer report stated: STARTER MOTOR FAULTY. ENGINE ELECTRICAL SYSTEM CONCERN: C/S: REPEAT START ATTEMPT INTERMITTEN WARNING LIGHTS. Please issue recall for the safety of all drivers.
NHTSA complaint #11749530 — an unverified report by a vehicle owner.
Upper Marlboro, MD
ELECTRICAL SYSTEM
Starter engine failure. Car failed to start multiple times. Major safety hazard that can cause a short circuit, melt wiring harnesses, and spark an engine bay fire posing an immediate threat to life. Problem was inspected and confirmed by a dealer. Multiple waring lamps and messages appeared. Dealer report stated: STARTER MOTOR FAULTY. ENGINE ELECTRICAL SYSTEM CONCERN: C/S: REPEAT START ATTEMPT INTERMITTEN WARNING LIGHTS. Please issue recall for the safety of all drivers.
NHTSA complaint #11749530 — an unverified report by a vehicle owner.
Upper Marlboro, MD
ENGINE
Starter engine failure. Car failed to start multiple times. Major safety hazard that can cause a short circuit, melt wiring harnesses, and spark an engine bay fire posing an immediate threat to life. Problem was inspected and confirmed by a dealer. Multiple waring lamps and messages appeared. Dealer report stated: STARTER MOTOR FAULTY. ENGINE ELECTRICAL SYSTEM CONCERN: C/S: REPEAT START ATTEMPT INTERMITTEN WARNING LIGHTS. Please issue recall for the safety of all drivers.
NHTSA complaint #11749530 — an unverified report by a vehicle owner.
at 66,700 milesAlhambra, CA
POWER TRAIN
The contact owns a 2021 BMW 540I. The contact stated that while driving at an undisclosed speed, the accelerator pedal was depressed; however, the vehicle failed to accelerate as intended. There was an abnormal sound coming from the vehicle before the vehicle lost motive power. No warning lights were illuminated. The contact stated that the vehicle failed to respond while in drive(D) or reverse(R). The vehicle was towed to the dealer, where it was diagnosed with a driveshaft failure. The contact was informed that the driveshaft needed to be replaced. The vehicle was not repaired. The contact referenced NHTSA Campaign Number: 21V046000 (Power Train); however, the VIN was not associated with the recall. The manufacturer was made aware of the failure. The contact was advised to contact the NHTSA Hotline to report the failure. The failure mileage was approximately 66,700.
NHTSA complaint #11727007 — an unverified report by a vehicle owner.
Powder Springs, GA
SERVICE BRAKES
In November 2025 my breaks quit working. I had AAA haul my car to a repair shop. They ran the codes on the car and found that it was related to a recall on 2021 BMW 540i's for the oil vacuum pump assembly, pan and gasket. I then had it towed to BMW and found out that my vin was not in the recall. BMW quoted me $4587 to repair this on a car with 45,000 miles. I then had it towed to a repair shop that replaced the oil vacuum pump assembly, oil pan, gasket and bolts for about $3700. I think that my vin should have been included in the recall. It was a obviously a common problem with my model and I should not have to pay this much on a car with 45,000 miles. I also had to pay $283.81 for BMW to diagnose it.
NHTSA complaint #11717479 — an unverified report by a vehicle owner.
Olathe, KS
SERVICE BRAKES
We notice the lose of braking power right after we started the car on 4/30 morning. The car was totally fine before that. took it to the BMW dealer they said the problem is "Vacuum/oil pump failing internally. fault for brake booster pressure switch, no brake boost" I find that there is a recall for the exact problem but it doesn't include my vehicle The "Part 573 Safety Recall Report 21V-598" stated that when It does happen it will cause damage to the oil/vacuum pump. I think recall 21V-598 should include my vehicle
NHTSA complaint #11658906 — an unverified report by a vehicle owner.
Edina, MNCrash
SERVICE BRAKES
Unintended car acceleration, with complete brake failure. No software warning icons in dash, no collision avoidance or ABS triggered even though car so equipped. Crashed into rear end of stationery vehicle,. [XXX] , MN police were called. Incident report # attached. (1st image) Western National Insurance Co. notified.Claim # attached (2nd image) Car will be inspected @ BMW dealership in Bloomington, MN 7/25/23. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA complaint #11533979 — an unverified report by a vehicle owner.
Edina, MNCrash
FORWARD COLLISION AVOIDANCE: WARNINGS
Unintended car acceleration, with complete brake failure. No software warning icons in dash, no collision avoidance or ABS triggered even though car so equipped. Crashed into rear end of stationery vehicle,. [XXX] , MN police were called. Incident report # attached. (1st image) Western National Insurance Co. notified.Claim # attached (2nd image) Car will be inspected @ BMW dealership in Bloomington, MN 7/25/23. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA complaint #11533979 — an unverified report by a vehicle owner.
Unintended car acceleration, with complete brake failure. No software warning icons in dash, no collision avoidance or ABS triggered even though car so equipped. Crashed into rear end of stationery vehicle,. [XXX] , MN police were called. Incident report # attached. (1st image) Western National Insurance Co. notified.Claim # attached (2nd image) Car will be inspected @ BMW dealership in Bloomington, MN 7/25/23. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA complaint #11533979 — an unverified report by a vehicle owner.
at 10,000 milesPhoenix, AZ
SEAT BELTS
The contact owns a 2021 BMW 540I. The contact stated that on multiple occasions, the front and rear passenger’s and driver’s side seat belts failed to detach after being connected. The contact stated that he forced the rear passenger’s side seat belt to detach with a screwdriver. No warning lights was illuminated. The vehicle was taken to the dealer where the dealer stated that candy was lodged in the buckle. The contact stated that the vehicle was not diagnosed or repaired. The manufacturer was notified of the failure and a case was opened. The failure mileage was approximately 10,000.
NHTSA complaint #11490291 — an unverified report by a vehicle owner.
Miami, FL
WHEELS
Intermittent vibration at highway speeds. Brought to the BMW dealership and they stated the right front wheel was out of round. I never hit a pothole or anything that would cause damage. The dealer "repaired" the wheel, but the problem still exists. Brought the vehicle back and am now told that BMW has started offering non-run flat tires on new cars. I feel that the run flat tires coupled with the low-profile wheels could be the issue. Also, feel that the wheels are poorly made and are prone to being warped.
NHTSA complaint #11488196 — an unverified report by a vehicle owner.
Miami, FL
STEERING
Intermittent vibration at highway speeds. Brought to the BMW dealership and they stated the right front wheel was out of round. I never hit a pothole or anything that would cause damage. The dealer "repaired" the wheel, but the problem still exists. Brought the vehicle back and am now told that BMW has started offering non-run flat tires on new cars. I feel that the run flat tires coupled with the low-profile wheels could be the issue. Also, feel that the wheels are poorly made and are prone to being warped.
NHTSA complaint #11488196 — an unverified report by a vehicle owner.
Atlanta, GA
ELECTRICAL SYSTEM:12V/24V/48V BATTERY
2021 BMW 540I. CONSUMER WRITES IN REGARDS TO MULTIPLE DEFECTS DUE TO BATTERY MANAGEMENT ISSUE. THE CONSUMER STATED THE VEHICLE HAS EXPERIENCED MULITPLE OCCASIONS OF FAILURES WITH THE BREAKING SYSTEM. THE DRIVER HAD TO PRESS THE PEDAL TO THE FLOOR IN ORDER TO STOP THE VEHICLE. THE EMERGENCY BRAKING SYSTEM ENGAGED WITHOUT WARNING, THE AUTOSTART ENGAGED INDEPENDTLY, AND LIGHTING/SPEAKER/SUNROOF MALFUNCTION.
NHTSA complaint #11449238 — an unverified report by a vehicle owner.