BMW 540I vs Chevrolet Express

Both cars' complete complaint records, side by side.

Read the totals carefully. NHTSA publishes no sales figures, so the car that sold more collects more complaints regardless of quality. The rows worth weighing are the proportions — the share of complaints that involved harm, and which part dominates.

Measure BMW 540I Chevrolet Express
Complaints on file 347 850
Model years covered 1994–2025 1995–2024
Worst model year 2018 2003
Best model year 1994 2011
Crashes reported 26 29
Fires reported 7 34
Injuries reported 14 19
Deaths reported 0 3
Most complained-about part Engine & Cooling Brakes
Share of complaints involving harm 13.5% 10%

BMW 540I by year

Complaints filed with NHTSA, by model year. Bar colour is the FaultScore grade: A B C D F ungraded

What breaks

Engine & Cooling 70 20.2%
Airbags 49 14.1%
Brakes 21 6.1%
Seats 19 5.5%
Seat Belts 18 5.2%
Steering 17 4.9%

Chevrolet Express by year

Complaints filed with NHTSA, by model year. Bar colour is the FaultScore grade: A B C D F ungraded

What breaks

Brakes 144 16.9%
Tires 60 7.1%
Airbags 41 4.8%