A recall of 27,720 BMW 5-series, 7-series, and 8-series vehicles for driveshaft connection issues.
BMW of North America, LLC (BMW) is recalling certain 2022-2026 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.
Affected VINs should be searchable now at the NHTSA website.
Here is the relevant information from the NHTSA Recall notice:
NHTSA ID Number: 26V525
Manufacturer: BMW of North America, LLC
Components: POWER TRAIN
Potential Number of Units Affected: 27,720
Estimated percentage with defect: 0.2%
Descriptive Information
Approximately 27,720 vehicles have been manufactured with connection between the driveshaft and rear axle differential that may, over time, be subject to excessive wear.
Basis for recall population determination: Vehicle assembly information and supplier production records were used to determine the number and production dates of potentially affected vehicles.
Recall component difference to non-recall component: The connection between the driveshaft and the rear axle differential may, over time, be subject to excessive wear.
Description of defect or noncompliance:
This safety recall involves the connection between the driveshaft and the rear differential. The connection may, over time, be subject to excessive wear.
Description of the safety risk, including crash, fire, death, injury:
In rare cases, this could lead to a loss of power to the rear wheels, which could increase the risk of a crash. In rare cases, if the vehicle is not secured by the parking brake, this could lead to a vehicle rollaway.
Description of the cause:
None stated.
Identification of any warning that can occur:
None stated.
Chronology
In December 2024, after noticing an increasing number of incidents from the field, an engineering investigation was initiated.
In the first quarter of 2025, a parts return program was created to obtain parts from the field for examination. At the time, the focus was on vehicles with high mileage which corresponded with the field incidents. Initial examinations included the interface between the driveshaft and the rear axle differential.
Between the first and third quarter of 2025, computer simulation (Finite Element Modeling (FEM)) was performed, including simulations of surface pressure at the interface between the driveshaft and the rear axle differential. A comprehensive review of enterprise-wide data (“Big Data”) was performed, including production data from applicable vehicle assembly plants. This data was compared across manufacturing plants to look for inconsistencies and/or anomalies. Bench tests were planned and conducted in order to reproduce damage observed from the field return parts, with the intent to understand how parts might have become damaged during vehicle operation. Metallurgical testing was performed to assess various material properties of drivetrain components.
Discussions and analyses with the supplier were conducted. Quality checks of their production process were performed, including parts inspections focused upon build quality.
Further reviews and analyses in 2025, and into the second quarter of 2026, included attempts to identify factors that could result in the outcomes as noted in the field incidents. This also involved comparisons to other vehicle types, driveshaft designs, and build configurations. Multi-Body Simulation (MBS) calculations of the bending angles for various axle configurations and propeller shaft mounting positions were performed.
The field continued to be monitored, and statistical forecasting was conducted including Weibull analyses. Further analyses and evaluations were conducted.
Vehicle assembly information and supplier production records were reviewed to determine the number and production dates of potentially affected vehicles.
On August 5, 2026, BMW decided to conduct a voluntary safety recall.
BMW has not received any reports, nor is BMW otherwise aware, of any accidents or injuries related to this issue.
Remedy
Description of Remedy
Remedy Type: Inspect, Replace
Description of remedy program:
The connection between the driveshaft and the rear axle differential will be checked, and either adhesive will be applied or, if necessary, the driveshaft and rear axle differential will be replaced.
How remedy component differs from recalled component:
Not stated.
Description of recall schedule:
Dealer notification is planned to begin and end on August 12, 2026.
Owner notification is planned to begin and end on October 2, 2026.
