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

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.

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?

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.

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.

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.

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.”

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.