Home » The Nuts And Bolts Of BMW’s Biggest Recall Ever: 1.5 Million Cars

The Nuts And Bolts Of BMW’s Biggest Recall Ever: 1.5 Million Cars

Bmw Recall Ts
ADVERTISEMENT

BMW is currently in the midst of its biggest recall ever, and with over 1.5 million cars affected, it is indeed a doozy. And not just because of the big number; the components involved are critical to say the least, lest anyone think we’re talking about defective cupholders here. Here’s everything you need to know about it.

According to the Associated Press, 270,000 of the 1.5 million cars subject to the recall are in the USA. Another 150,000 more sit in BMW’s home nation of Germany; 70,000 are in Korea; and another 60,000 are in France. The country most affected by the recall is China, with 370,000 cars headed back to the dealer – if they’re not there already, as BMW says roughly 320,000 cars of the recall population are still sitting on lots.

Vidframe Min Top
Vidframe Min Bottom

All of these vehicles have a potential issue with the Integrated Braking System (IBS). Specifically, the system’s brake module “may not function as designed,” according to a statement provided to BMWBlog. The system is designed to help a driver maintain a consistent brake feel via an electric actuator and incorporates the brake control function, actuation, and force assistance into a single module. The part in question is one made by Continental AG.

Alfa Romeo uses a similar Continental-built IBS system on the Giulia. In the video above we see that the system can save weight and provide good feedback to the driver. BMW doesn’t have a video that demonstrates it, and the Giulia is gorgeous so why not learn about it this way?

ADVERTISEMENT

Here’s how BMW describes the issue in its documents to NHTSA.

The integrated brake (IB) system may not function according to specifications, and a reduction in the power assist function could occur. If this reduction occurs, the Antilock Brake System (ABS) and Dynamic Stability Control (DSC) system may not function.

Fully mechanical braking is not affected, and is still available to slow and stop the vehicle. The emergency function of brake force distribution is also not affected, and is available to help control vehicle stability. Also, the parking (emergency) brake would be automatically activated to aid in braking performance and help maintain vehicle stability and control.

In the even that IBS fails or the CPU detects a fault, it will send a warning light to the dash. At the same time, one’s brakes might lose the power assist feature, increasing braking distance. BMW doesn’t know of any injuries or accidents related to the problem as we publish this story, but we’ll update as needed.

The recall population includes the BMW 5-Series, 7-Series, X-Series (excluding the X3 and X4), Mini Cooper, Mini Countryman, and the Rolls Royce Spectre. All of the affected cars have a build date between June 2022 and August 2024. According to Continental AG, sensors in the vehicle should detect the potential issue “well before it occurs,” so in theory, owners will have some warning before they have no power-assisted brakes.

Screenshot 2024 09 16 133422

For now, the plan is to replace the module altogether. Workers will first confirm whether or not the part has been checked for quality. In cases where it hasn’t been, they’ll perform a test to see if certain plugs loosen and tighten within technical specifications. They’ll check the plug bores for thread damage and particles, too. Should all of that check out okay, they’ll install the new part.

ADVERTISEMENT

Screenshot 2024 09 16 135412

Screenshot 2024 09 16 135420
The IBS trouble is related to these threaded plugs.

Interestingly, BMW already recalled 76,000 cars in February for this exact same issue, but evidently, that fix wasn’t enough. “Unfortunately, it was determined that vehicles that received replacement parts in that recall must have those parts replaced,” confirmed the automaker confirmed to BMW Blog.

Screenshot 2024 09 16 135433
This photo shows a threaded bore with its plug removed.

BMW began investigating the issue in October of 2023 but it began hearing about cases it now believes that are connected as far back as June of 2022. Here’s a quote from the official chronology report to the NHTSA.

“Between June 2022 and February 2024, BMW became aware of approximately 48 customer complaints, concerns, and/or instances, 100 dealer field reports, and 459 warranty claims that relate, or may relate, to the issue identified in this report.”

According to Bloomberg, the part manufacturer tracked the whole thing back to one singular plant.

“Continental traced the defect back to a plant in Hungary. Workers producing the brakes’ circuit boards there failed to maintain a sufficiently clean environment, leaving smudges or dust on the components that hampered the system’s performance, according to people familiar with the matter.”

Bremse Mkc2

ADVERTISEMENT

As we mentioned at the outset, this recall has led BMW to lower its guidance for earnings before interest and taxes margin from 8-10 percent down to 6 or 7 percent. It also lowered its annual return on capital employed to 11-13 percent instead of 15-20 percent.

Notably, BMW also says that the change came in part due to “ongoing muted demand” in China where domestic competition is fierce and only getting harder to beat. As such, it’s also lowered its guidance on total deliveries for the year from what it called a “slight increase” to a “slight decrease” though it didn’t provide specific figures.

For now, owners concerned about whether or not their vehicle is a part of the recall can contact their local dealer or search for their vin on NHTSA’s website.

Share on facebook
Facebook
Share on whatsapp
WhatsApp
Share on twitter
Twitter
Share on linkedin
LinkedIn
Share on reddit
Reddit
Subscribe
Notify of
30 Comments
Inline Feedbacks
View all comments
Anthony Magagnoli
Anthony Magagnoli
22 days ago

we see that the system can save weight and provide good feedback to the driver.”
No. They all give TERRIBLE feel to the driver. Anything the driver feels is utterly simulated.

Danny Zabolotny
Danny Zabolotny
23 days ago

The techs at my dealership are stoked about this because it pays way more hours than it actually takes to do the job. So at least somebody’s having a good time with this.

James Carson
James Carson
23 days ago

Gotta love book rate!

RaisinK
RaisinK
23 days ago

As someone who is currently dealing with BMW for the R56 Mini Cooper footrest module recall. Kinda relieved here as uncontrollable window and light is better than uncontrollable brakes….. Lol

Last edited 23 days ago by RaisinK
Hugh Crawford
Hugh Crawford
24 days ago

That link to
https://www.continental.com/en/press/studies-publications/technology-dossiers/brake-systems-of-the-future/

In the article “this module” explains a lot, and my firs thought is that I really don’t like the whole idea at all, but it’s right in there with stability control, ABS, and power steering in the basket of things that are probably generally good but have terrible failure modes and are one of the reasons I like older cars.

I used to have a Volvo 740 and sometimes the sensors on the brakes would get dirty and the ABS would engage on dry pavement and it was pretty scary. Fortunately I never hit a pedestrian or another car.

Angrycat Meowmeow
Angrycat Meowmeow
24 days ago

I had an ’18 Giulia with Conti IBS and it failed. I got in the car, pushed the brake to start, and the pedal just went straight to the floor. Got it towed to the dealer because I could feel the reduced braking just pulling out of my garage. Zero warning lights on the dash. When they finally got the part and installed it they couldn’t figure out how to program it, so they contacted Alfa tech support. Alfa was more than happy to provide instructions, but they were all in Italian and unfortunately none of the American technicians at the Saturn Alfa Romeo dealer could read Italian, so it sat for a while longer. All in it was over a month, maybe more like 2 months.

Actually, now that I think about it, this happened twice. I don’t remember what the resolution was the first time this happened but it wasn’t long before the big failure. I think they just did a system reset or something and gave it back.

Cheap Bastard
Cheap Bastard
24 days ago

BMW’s really on a roll here! There’s no stopping them now!

James Carson
James Carson
24 days ago

The old toss Jan under the bus gambit. Like what’s wrong with a master cylinder, pedal, some lines, been a viable solution for decades without cpus, extra modules and an AI dialing home for a brake or not brake committee meeting.

Hugh Crawford
Hugh Crawford
24 days ago
Reply to  James Carson

Sadly, that has not been available since 2012 and mandatory ABS.

1978fiatspyderfan
1978fiatspyderfan
24 days ago

Nuts and bolts? I say Nuts in Vise!

Last edited 24 days ago by 1978fiatspyderfan
Harmon20
Harmon20
24 days ago

Huh. You say BMW crapped the bed because of bad IBS?

Oof. Been there, brother, and it ain’t no joke. I hate to hear that for them. I wouldn’t wish it on my worst enemy.

George CoStanza
George CoStanza
24 days ago
Reply to  Harmon20

This is the only instance I know of where you get a Code Brown from the IBS NOT kicking in!

Last edited 24 days ago by George CoStanza
Mrbrown89
Mrbrown89
24 days ago

“Continental traced the defect back to a plant in Hungary. Workers producing the brakes’ circuit boards there failed to maintain a sufficiently clean environment, leaving smudges or dust on the components that hampered the system’s performance, according to people familiar with the matter.”

This could be avoided if Six Sigma was followed (Taking a Green Belt certification as we speak lol) #help

Last edited 24 days ago by Mrbrown89
Alpine 911
Alpine 911
24 days ago
Reply to  Mrbrown89

Or even a simple 5S

Abdominal Snoman
Abdominal Snoman
24 days ago

Also, the parking (emergency) brake would be automatically activated to aid in braking performance and help maintain vehicle stability and control.

Every time I’ve activated the parking brake in a moving car it certainly did not “help maintain vehicle stability”…

The Clutch Rider
The Clutch Rider
24 days ago

but did women like it?

Crank Shaft
Crank Shaft
24 days ago

How the bores relate to the boards still completely eludes me after carefully reading this post. Could we have some better info?

Signed,

Curious

Mechjaz
Mechjaz
24 days ago
Reply to  Crank Shaft

It’s the circuit bores, obviously!

(I’ve reread it and have no freaking idea either. I watched the Alfa video as well as following through to BMWblog, I got nothin)

Shooting Brake
Shooting Brake
24 days ago

Up to now, I always thought that “IBS” was a Gastrointestinal disorder 😉

Last edited 24 days ago by Shooting Brake
Data
Data
24 days ago
Reply to  Shooting Brake

If you stomp on the brakes and nothing happens, you may well have a gastrointestinal disorder shortly.

Shooting Brake
Shooting Brake
24 days ago
Reply to  Data

Indeed you might! lol!

Spikersaurusrex
Spikersaurusrex
24 days ago
Reply to  Data

IBS – D I believe.

Drive By Commenter
Drive By Commenter
24 days ago

Surprised to see it’s not a defective turn signal stalk. And, who needs brakes anyhow?

Querty
Querty
24 days ago

As a BMW driver I’d like to know where this “turn signal stalk” is located to check. Never used them before, but want to be sure it won’t throw a irremovable warning message like the (also useless) SOS Call System threw on me

Angry Bob
Angry Bob
24 days ago
Reply to  Querty

Turn signals on my 540i don’t work.

I mean they actually don’t work.

Andy Individual
Andy Individual
24 days ago
Reply to  Angry Bob

Did you remember to pay your subscription?

DONALD FOLEY
DONALD FOLEY
24 days ago

Does Bob remember his hand signals?

Captain Muppet
Captain Muppet
24 days ago
Reply to  Querty

The lever you pull to flash high beams while tailgating can also move up and down to cause half the hazard lights to flash. No one knows why.

Source: I found a description of the feature hand written inside the back cover of my E34 535 handbook.

Hugh Crawford
Hugh Crawford
24 days ago
Reply to  Captain Muppet

So that’s a feature of the optical horn that has been extended to the optical hand wave?

CanyonCarver
CanyonCarver
24 days ago

Nobody would know it was defective because they aren’t ever used

30
0
Would love your thoughts, please comment.x
()
x