The 1999 BMW 540i has 1 NHTSA recall campaign affecting an estimated 1,615 vehicles. Recall repairs are always free at any authorized dealer. Owners have filed 29 complaints with NHTSA, most often about the electrical system. Last updated July 5, 2026.
VEHICLE DESCRIPTION: PASSENGER VEHICLES. THE THICKNESS OF THE MAIN POSITIVE ELECTRICAL CABLE (GENERATOR TO STARTER) INSULATION IS LESS THAN SPECIFIED, MAKING IT SUSCEPTIBLE TO BEING ABRADED OR CUT BY THE CLIP THAT SECURES THE CABLE TO THE GENERATOR.
Consequence
THE CABLE INSULATION CAN BE WORN AWAY, EXPOSING THE WIRE. THE WIRE COULD CONTACT THE CLIP OR A SHORT CIRCUIT COULD OCCUR.
Remedy
DEALERS WILL APPLY A THICKNESS OF INSULATING TAPE TO THE CABLE IN THE AREA OF THE CLIP, AND INSTALL A REVISED CLIP.
Complaints by component
ELECTRICAL SYSTEM
4
1crashes
ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY
3
STEERING
3
ENGINE AND ENGINE COOLING:COOLING SYSTEM
2
LATCHES/LOCKS/LINKAGES
2
POWER TRAIN:AUTOMATIC TRANSMISSION
2
SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP
2
AIR BAGS
1
AIR BAGS:SIDE/WINDOW
1
ELECTRONIC STABILITY CONTROL (ESC)
1
Total complaints29
What owners report
Verbatim reports filed with NHTSA, lightly edited for readability and with personal
information removed.
“Tl* the contact owns a 1999 bmw 540i. The contact stated that the vehicle failed to start. The vehicle was towed to an independent mechanic, where it was diagnosed that the positive battery cable was burned. The vehicle was repaired. The vehicle was not included in nhtsa campaign number: 99v004000…”
“My 1999 bmw 540i was just sitting in the driveway and we heard a loud thud. I walked out to the bmw and noticed the passenger airbag had deployed for no reason, shattering the windshield. If this had happened while driving, it could have caused a serious accident. *tr”
“My 1999 bmw 540i was just sitting in the driveway and we heard a loud thud. I walked out to the bmw and noticed the passenger airbag had deployed for no reason, shattering the windshield. If this had happened while driving, it could have caused a serious accident. *tr”
“Power steering pump broke causing accessory belt to be thrown from engine at highway speeds, resulting in loss of steering and power. *tr”
“Power steering pump broke causing accessory belt to be thrown from engine at highway speeds, resulting in loss of steering and power. *tr”
“Power steering pump broke causing accessory belt to be thrown from engine at highway speeds, resulting in loss of steering and power. *tr”
“My transmission would not accelerate or move. I had the trans rebuild and 2 years later the same problem. The trans has lost gears 1-3 and reverse, multistate repaired the trans again 2013, ifor the second time, it never worked after repairs. The engine light stays on, bmw says I need new trans…”
“My transmission would not accelerate or move. I had the trans rebuild and 2 years later the same problem. The trans has lost gears 1-3 and reverse, multistate repaired the trans again 2013, ifor the second time, it never worked after repairs. The engine light stays on, bmw says I need new trans…”
Recall, complaint, and investigation records from official NHTSA datasets (FLAT_RCL,
FLAT_CMPL, FLAT_INV), synced weekly. Counts reflect NHTSA records for the 1999 BMW 540i as of
July 5, 2026. Complaint narratives are consumer-submitted and unverified. This page
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