The BMW E36 Z3 1996-2002 (I have the 1998 1.9) are prone to having a separation of the Rear subframe from the differential causing the drivetrain to hang off the vehicle and/or rip out of the trunk's weak aluminum sheet subframe. BMW Germany has acknowledged the problem for a few individuals over the past decade and a half and kept it on the low for them to not spread it further. BMW North America fails to acknowledge the design flaw during their manufacturing process in the North American Plant during the late 90s. The Spot Welds' quality is subpar and worrisome as this catastrophic failure of the subframe to driveline structure has various ways of presenting it self which chiefly includes popped spot welds in the truck which comes hand in hand with a cracked differential ear bracket. * To simply understand why this happens: The issue is that the metal of the trunkfloor is too thin and not adequete at holding up to the forces of the differential tugging at it. There have been documented cases of similarly "repaired" Z3's that end up basically pulling out and/or deforming the entire trunkfloor panel. The metal panel the diff crossmember is structurally tied to (and the trunkfloor itself which is above it) is simply too weak for the forces being applied through it. Adding more welds simply changes where the failure occurs - from pulling out spotwelds, to deforming the trunk floor/crossmember itself if there are too many welds for them to be able to be pulled out. There are a few kits going around that other owners have addressed to their vehicles for a few thousand dollars which includes welding and a re-fabrication of the trunk floor's structure to the subframe/chasis. It has two "caps" that sit on the framerails at either side and a "crossmember" piece which is a strong piece of metal that spans between the two frame rails and sits on top of the "caps". When installed, the differential ends up tugging at the crossmember, which then distributes the forces.....
NHTSA complaint #11461944 — an unverified report by a vehicle owner.
I HAVE A 1998 Z3 M ROADSTER AND THE TRUNK WELDS HOLDING THE SUBFRAME IS FAILING. THIS IS A COMMONLY DOCUMENTED ISSUES. BMW DEALERS ACKNOWLEDGE THE ISSUE BUT BMW NORTH AMERICA WILL NOT FIX IT. THIS IS A WELDING/MANUFACTURING DEFECT THAT CAN LEAD TO THE DIFFERENTIAL AND SUSPENSION COMPONENTS IN THE REAR TO COMPLETELY SEPARATE.
NHTSA complaint #11165993 — an unverified report by a vehicle owner.
VERY WELL KNOWN FAILURE, JUST SEARCH FOR "BMW Z3 SUBFRAME FAILURE". IT IS A DESIGN FLAW BY BMW THAT AFFECTS A LOT OF Z3'S THROUGH ALL MODEL YEARS. MINE STARTED TO POP ONE WELD AT 88K MILES. IT CAN CAUSE THE REAR ALIGNMENT TO BE OFF, IN WORST CASE THE TRUNK FLOOR IS TORN OUT AND THE DIFFERENTIAL FALLS TO THE GROUND. CLUNKING FROM THE BACK WHILE SHIFTING IN THE FIRST TWO GEARS IS ONE INDICATOR THIS DAMAGE IS NOT FAR AWAY. THIS IS ONE FORUM THREAD THAT DESCRIBES THE ISSUE WELL: HTTPS://WWW.BIMMERFORUMS.COM/FORUM/SHOWTHREAD.PHP?1979601-SUBFRAME-TRUNK-FLOOR-DIFFERENTIAL-MOUNT-FAILURE
NHTSA complaint #11032127 — an unverified report by a vehicle owner.
TL* THE CONTACT OWNS A 1999 BMW Z3. AFTER THE VEHICLE WAS STARTED AND PLACED INTO REVERSE, A CLANKING SOUND EMERGED FROM THE REAR END WITHOUT WARNING. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE VIN WAS EXCLUDED FROM NHTSA CAMPAIGN NUMBER: 99V272000 (POWER TRAIN). THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 140,000.
NHTSA complaint #10874771 — an unverified report by a vehicle owner.
THE REAR DIFFERENTIAL HOUSING IS SEPARATING FROM THE SUBFRAME OF THE CAR, UNDER OR NEAR THE TRUNK AREA. THIS IS A WELL DOCUMENTED ISSUE WITH THE Z3 SERIES OF VEHICLES. THIS COULD BE A SAFETY HAZARD WHILE OPERATING THE VEHICLE IF THE READ DIFFERENTIAL SEPARATES FROM THE SUBFRAME, AND COULD CAUSE A HAZARD TO OTHER MOTORIST. THIS APPEARS TO BE DUE TO A DESIGN FLAW. THE FRAME WAS DESIGNED FOR A 1.9L ENGINE, AND BMW DID NOT REDESIGN THE SUBFRAME TO ALLOW FOR THE LARGER ENGINES IT LATER SOLD IN THE Z3 SERIES OF CARS. BMW ALSO HAD THIS SAME ISSUE ON 3XX SERIES OF VEHICLES, AND AGREED TO REPAIR THOSE CARS DUE TO A CLASS ACTION LAW SUITE SETTLEMENT. BMW SHOULD BE HELD ACCOUNTABLE FOR THE DESIGN ISSUE, AND ACKNOWLEDGE THE SAFETY HAZARD.
NHTSA complaint #10676809 — an unverified report by a vehicle owner.
ON 24JUN2011, I SWERVED FROM A PARALLEL LANE TO AVOID BEING SIDESWIPED. NO CONTACT WAS MADE BETWEEN VEHICLES. HOWEVER, I NOTICED A NOISE COMING FROM THE REAR OF THE VEHICLE. THE VEHILE HAS A MANUAL TRANSMISSION. I TOOK THE VEHICLE TO AN AUTO BODY REPAIR SHOP. AFTER EXAMINING THE VEHICLE THEY TOLD ME THAT: THE FLANGE/BRACKET THAT HELD THE DIFFERENTIAL IN PLACE HAD A COMPLETE HAIR-LINE FRACTURE; AND, THAT A SUBSTANTIAL NUMBER OF SPOT WELDS HOLDING THE BODY ON TO THE FRAME HAD FAILED. I MADE CONTACT WITH THE LOCAL BMW DEALERSHIP MCGRATH BMW, OCATED IN WESTMONT, IL AND TOLD THEM OF THE INCIDENT. THEY STATED THAT THEY DID NOT UNDERTAKE BODY REPAIRS AND DIRECTED ME TO A FIRM WHICH DID ALL TYPES OF BODY AND STRUCTURAL REPAIRS AND WAS ACCREDITED BY BMW. I WAS GIVEN AN ESTIMATE FOR THE REPAIR OF BETWEEN $5,000-$6,000, AND WAS TOLD THAT THERE WAS NO PROGRAM OFFERED BY BMW TO SHARE IN THE COST OF THE FLANGE/BRACKET AND BODY REPAIR. I WENT BACK TO MY LOCAL BODY SHOP AND TOLD THEM TO ESTIMATE THE COST AND I ALSO REPORTED THE PROBLEM TO MY AUTO INSURANCE (STATE FARM). AN ADJUSTER FROM STATE FARM REVIEWED THE FAILURES AND STATED THAT THE CONDITION WAS ONE OF A PROBLEM IN MANUFACTURE AND NOT COVERED BY MY AUTO INSURANCE. MY BODY SHOP THEN GAVE ME AN ESTIMATE OF A NOT TO EXCEED FIGURE OF APPROXIMATELY $2,500. I TOLD THEM TO UNDERTAKE THE REPAIR. THE FLANGE/BRACKET HAS BEEN REPLACED AND REINFORCED AND THE BODY AND FRAME HAVE SINCE BEEN REWELDED AT A TOTAL COST TO ME OF $1600. ADDITIONALLY, I SPENT AN ADDITIONAL $100 FOR A ALIGNMENT (FIRESTONE OF COUNTRYSIDE, IL) THE LOCAL BODY SHOP IS DOUGLAS AUTO BODY, 4015 EBERLY AVENUE, BROOKFIELD, IL (708) 485-7774 - THEY ARE A BODY AND STRUCTURAL REPAIR SHOP APPROVED BY STATE FARM INSURANCE. THIS VEHICLE HAS BEEN USED BY ME AS A STREET VEHICLE AND NOT FOR RACING OR TRACK USE OF ANY KIND. THE FAILURES SEEM TO BE A MFG. DESIGN FLAW.
NHTSA complaint #10436004 — an unverified report by a vehicle owner.
I PURCHASED A USED 1998 BMW Z3 WITH THE 1.9 LITER ENGINE ON 10/14/2010 WITH 90564 MILES. IN MID NOVEMBER I TOOK THE CAR TO A MECHANIC FOR A CHECK ENGINE LIGHT WHICH WAS SERVICED. THE MECHANIC INFORMS ME THERE IS A PROBLEM WITH Z3'S ALONG WITH OTHER MODEL BMW'S WITH THE WAY THE REAR DIFFERENTIAL IS ATTACHED. THE PROBLEM SEEMS TO BE FLEXING IN THE SHEET METAL WHERE THE DIFFERENTIAL IS ATTACHED CAUSING FAILURE OF THE SPOT WELDS HOLDING THE WHOLE ASSEMBLY TOGETHER. HE SHOWED ME IN MY TRUNK WHERE TWO OF THE SIX SPOT WELDS HAD BROKEN. I HAVE RESEARCHED THIS ON THE DIFFERENT BMW FORUMS AND BMW IS CLAIMING THIS FAILURE IS DUE TO PERFORMANCE MODIFICATIONS OR CARS THAT HAVE BEEN TAKEN TO A TRACK OR AUTOCROSS. I DO NOT KNOW THE PREVIOUS HISTORY OF MY CAR BUT IT APPEARED TO HAVE BEEN TAKEN CARE OF. ON 6/30/2011 I HAD THE CAR IN THE SHOP AGAIN FOR SERVICE WORK AND MY MECHANIC FOUND TWO MORE BROKEN WELDS AND SOME SEPARATION IN THE REAR CHASSIS. THIS CAR IS PRETTY MUCH UN-DRIVABLE NOW DUE TO THIS CONDITION. I UNDERSTAND THERE IS A COUPLE OF COMPANIES THAT MAKE A REPAIR KIT FOR THIS THAT WILL STRENGTHEN THE TRUNK AREA AND PREVENT THIS FROM HAPPENING AGAIN.
NHTSA complaint #10415652 — an unverified report by a vehicle owner.
TL* THE CONTACT OWNS A 1999 BMW Z3. THE CONTACT STATED THAT THE VEHICLE WAS INCREASINGLY HARD TO CONTROL AND THE VEHICLE WAS TAKEN TO A LOCAL REPAIR FACILITY FOR AN ALIGNMENT. THE MECHANIC ADVISED THE CONTACT THAT THE REAR DIFFERENTIAL HAD FAILED AND WAS CAUSING THE WHEELS TO FRACTURE FROM THE SUB FRAME. THE MECHANIC ALSO ADVISED THE CONTACT OF THE RECALL ASSOCIATED WITH NHTSA CAMPAIGN ID NUMBER: 99V272000 (POWER TRAIN: DRIVELINE: DIFFERENTIAL UNIT). THE MANUFACTURER WAS CONTACTED AND THE CONTACT WAS ADVISED TO HAVE THE VEHICLE TOWED TO THE DEALER. THE VEHICLE WAS TOWED AND THE CONTACT WAS AWAITING DIAGNOSIS AND REPAIRS. THE FAILURE AND CURRENT MILEAGE WAS 105,000.
NHTSA complaint #10378668 — an unverified report by a vehicle owner.
DT*: THE CONTACT STATED WHILE DRIVING 70 MPH DURING CLEAR CONDITIONS, THE FRONT DRIVER SIDE AIR BAG DEPLOYED WITHOUT WARNING OR IMPACT TO THE VEHICLE. THERE WAS NO DEBRIS OR POTHOLES PRESENT. THE CONTACT SUFFERED CUTS, BRUISING AND SCARING TO THE LEFT ARM. THE CONTACT DROVE TO THE HOSPITAL. THE SERVICE DEALER AND MANUFACTURER WERE NOTIFIED AND PHOTOS WERE TAKEN OF THE VEHICLE AND INJURIES. UPDATED 11/16/2006 -THE GAS GAUGE AND ODOMETER WERE INOPERATIVE. THE DEALER REPLACED THE INSTRUMENT CLUSTER. THE DRIVER'S DOOR GRAB HANDLE WAS REPLACED. THE REAR SHOCKS AND MOUNTS WERE REPLACED. THERE WAS A POWER STEERING LEAK. THE DEALER REPLACED THE POWER STEERING HOSE RES TO PUMP. THE DEALER REPLACED THE FLEX COUPLER ON THE DRIVE SHAFT.
NHTSA complaint #10171793 — an unverified report by a vehicle owner.
I PURCHASED MY CAR FROM ROSE IMPORTS IN VALLEJO, CA. ON 08-22-2006. APPROXIMATELY 1 MONTH LATER, I STARTED TO HEAR A NOISE FROM THE REAR. I WOULD HEAR IT OCCASIONALLY. ON 10-10-2006, I WAS DRIVING HOME ON I-80 AND AS I WAS DRIVING, SUDDENLY I HEAR A LOUD "POP". I PULL OVER AND DID A VISUAL CHECK BUT FOUND NOTHING I COULD SEE SO I CONTINUED TO DRIVE HOME AND HEARD METAL SOUNDS COMING FROM THE BACK. THE NEXT DAY WHILE DRIVING TO WORK, I CONTINUED TO HEAR THE SOUND AND WHEN I RETURNED HOME, ME AND A FRIEND LIFTED THE CAR AND THAT'S WHEN I DISCOVERED THE SNAP OR BREAK IN THE DIFFERENTIAL SUPPORT BRACKET. IT HAS COMPLETELY SEPARATED FROM THE DIFFERENTIAL. THE DEALER WHERE I PURCHASED THE CAR TOLD ME GOOD LUCK. THEY'RE NOT GOING TO DO ANYTHING SINCE IT PASSED THEIR SAFETY INSPECTION. I CALLED MY LOCAL BMW DEALER AND SPOKE TO THE SERVICE DEPT. AND THEY TOLD ME IT WAS NOTHING THEY CAN OR WILL DO BECAUSE IT'S 86K MILES AND OUT OF WARRANTY. NOW I'M STUCK WITH A CAR I JUST PURCHASED AND HAVE A MAJOR BILL 2 MONTHS LATER.
NHTSA complaint #10170795 — an unverified report by a vehicle owner.
NIELLO BMW OF SACRAMENTO CHECKED MY Z3 2000 FOR TRACTION CONTROL LIGHT IS ON ADVISE, AND SOME FLUTTERING NOISE CAME OUT DURING ACCELERATION. THEY FOUND OUT THAT THERE'S METAL SHAVINGS IN THE DIFFERENTIAL. THEY REPAIRED IT AND REPLACED IT WITH NEW ONE AS WHAT THEY ADVISED TO ME, PLUS THEY REPLACED THR BRAKE PADS, ROTORS, SENSOR DRIVE BELTS, COVER AIR BAG AND THAT COST $3200.18 WHICH I PAID. I QUESTIONED THEM IF THAT'S STILL BE COVERED BY THE WARRANTY SINCE I BOUGHT THAT CAR IN MAY 1999, AND THEY SAID," NO IT'S NOT UNDER WARRANTY." SO I PAID THE WHOLE AMOUNT OF $3200.18. SO I DROVE MY CAR AND IN A MATTER OF DAYS THE CAR BROKE AGAIN, STOPPING IN THE MIDDLE OF FREEWAY, AND THAT TIME I HEARD SOME FLUTTERING NOISE AGAIN UNDERNEATH, WHICH SCARED ME. SO I IMMEDIATELY CALLED SOME HELP AND TOOK MY CAR TO NIELLO BMW IN SACRAMENTO FOR REPAIR AND IT THEM A WEEK TO REPAIR MY CAR. AFTER IT WAS BEING REPAIRED I TRADED IT IN WITH LEXUS RX 330 IN ROSEVILLE SINCE I'M SCARED ALREADY DRIVING BMW AND DON'T TRUST THAT CAR AGAIN.
NHTSA complaint #10149470 — an unverified report by a vehicle owner.
DT: 1996 BMW Z3. THE CONSUMER STATES THE VEHICLE HAS AN INCORRECTLY MACHINED GUIDE SLEEVE IN THE MANUAL TRANSMISSION. THIS CAUSES THE TRANSMISSION TO JUMP OUT OF GEAR WITHOUT ANY WARNING. THE VEHICLE HAS NOT BEEN TAKEN TO THE DEALERSHIP, BUT HE HAS CONTACTED THE MANUFACTURER ABOUT THE PROBLEM. THE MANUFACTURER STATES THERE IS NO RECALL. THE PROBLEM STARTED ON MAY 23, 2001. THERE HAS BEEN NOTHING DONE TO CORRECT THE PROBLEM. THE PROBLEM IS INTERMITTENT, AND OCCURS ONLY IN FIRST GEAR.
NHTSA complaint #10136997 — an unverified report by a vehicle owner.
THE VEHICLE WAS PARKED WHEN THE DRIVER NOTICED THAT THE DIFFERENTIAL WAS HANGING FROM UNDERNEATH THE VEHICLE. THE DRIVER HAD THE VEHICLE TOWED TO THE DEALER. THE MECHANIC INFORMED THE DRIVER THAT THE REAR TRUNK SUB FRAME NEEDED REPLACEMENT AND WELDING. *NM
NHTSA complaint #10107383 — an unverified report by a vehicle owner.
I OWN A 1999 BMW Z3 2.3 ROADSTER. THE DIFFERENTIAL MOUNT HAS TORN AWAY FROM THE UNDERBODY OF THE CAR WHERE IT WAS WELDED WHEN DESIGNED. THIS IS THE THIRD COMPLAINT ABOUT THIS PARTICULAR DEFECT ON THIS WEBSITE BUT THERE ARE SEVERAL MORE ON BIMMERFEST.COM. BMW NA SHOULD BE MADE AWARE OF THIS DESIGN FLAW AND FORCED TO DO A RECALL ON ALL CARS THEY MADE WITH THIS FLAW. I WILL SEEK ALL NECESSARY LEGAL ACTION TO HOLD THEM ACCOUNTABLE. YOU DON'T PAY $40,000 FOR A CAR THEY CLAIM AS THE BEST CAR ON THE ROAD TO HAVE A MAJOR SAFETY ISSUE LIKE THIS EXIST.
NHTSA complaint #10100977 — an unverified report by a vehicle owner.
THE DIFFERENTIAL MOUNT ON MY 1999 BMW Z3 COUPE 2.8 HAS CRACKED. SHOULD THIS MOUNT FAIL COMPLETELY, I FEAR THAT SERIOUS HARM MAY COME TO ANOTHER DRIVER, PASSENGER OR MYSELF.
NHTSA complaint #10062290 — an unverified report by a vehicle owner.
MANUAL TRANSMISSION...VIOLENTLY POPS OUT OF FIRST GEAR TO NEUTRAL POSITION UPON ACCELERATING FROM STOP..DANGEROUS, AS CAR BEHIND EXPECTS CONTINUED FORWARD MOTION, BUT MUST INSTEAD, AWAIT ANOTHER SHIFT INTO FIRST AND POSSIBLE REPEAT OF POPPING OUT OF GEAR. HAPPENS OFTEN. SIGNIFICANT EXPENSE TO REPAIR. SHOULD DEALER PAY FOR ALL?
NHTSA complaint #10002732 — an unverified report by a vehicle owner.
WHILE DRIVING 50-60 MPH WHEELS LOCKED UP, CAUSING VEHICLE TO VEER FROM SIDE TO SIDE, FINALLY SPUN AROUND. VEHICLE WAS TOWED TO DEALERSHIP, IT WAS DETERMINED THAT DIFFERENTIAL HAD LOCKED UP AND NEEDED TO BE REPLACED.
NHTSA complaint #8002952 — an unverified report by a vehicle owner.
WHILE TRAVELING APPROXIMATELY 40 MPH REAR DIFFERENTIAL UNIT LOCKED UP, CAUSING RIGHT/ REAR TIRE TO STOP SPINNING. DEALERSHIP IS EXAMINING VEHICLE AND MAKING ALL NECESSARY REPAIRS. PLEASE PROVIDE ANY ADDITIONAL INFORMATION / DOCUMENTATION.
NHTSA complaint #8001550 — an unverified report by a vehicle owner.