2021 BMW 540i Reliability Data: Problems & Recalls
Good The 2021 BMW 540i has a complaint index of 38, ranking 6th worst among 9 model years, with a Good verdict. It had 9 complaints, 6 recalls, and 1 crash, with brakes and transmission/powertrain each accounting for 33% of complaints.
Based on NHTSA complaints per model-year, not a reliability rating. Methodology
YearToAvoid Scorecard
- Complaint Index
- 38/100
- #6 of 9 540i years
- Verdict
- Good
- vs. other years of this model
- Complaints
- 9
- unique NHTSA reports
- Recalls
- 6
- distinct NHTSA campaigns
- Crashes
- 1
- reported in complaints
- Fires
- 0
- Injuries
- 0
- Top issue
- Brakes
- NHTSA overall rating
- Not rated
- EPA combined MPG
- 26.5
- 24 city / 31.5 hwy
- Injuries / deaths
- 0 / 0
Top 2021 BMW 540i problems
Share of this year’s NHTSA complaints by component group. Groups with 15+ complaints have their own page.
- Brakes3 (33%)
- Transmission & Powertrain3 (33%)
- Electrical System2 (22%)
- Engine1 (11%)
- Collision Avoidance & Cameras1 (11%)
- Seat Belts1 (11%)
- Steering1 (11%)
- Suspension, Wheels & Tires1 (11%)
A complaint can list more than one component, so shares add up to more than 100%. Shares are % of complaints.
What owners report
- Brakes fail suddenly with no ABS or collision-avoidance warning, sometimes leading to a crash into another vehicle.
- Battery management issues trigger unexpected emergency braking, independent auto-start, and lighting malfunctions.
- Front and rear seat belts fail to detach after being connected, requiring manual force to release.
- Intermittent vibration at highway speed traced to a wheel that was out of round, with the issue persisting after dealer repair.
- Loss of brake boost linked to a vacuum/oil pump failure, described by owners as matching a known recall condition.
- The accelerator pedal fails to respond and the vehicle loses motive power after an abnormal sound, at a median mileage of 66,700 miles.
2021 BMW 540i recalls
6 NHTSA recall campaigns list this model year.
- NHTSA 26V525000Aug 12, 2026Transmission & Powertrain27,720 vehicles
Power train:driveline:driveshaft
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.
Risk: An unexpected loss of drive power can increase the risk of a crash. In addition, a damaged driveshaft can result in a vehicle rollaway if the parking brake is not applied, increasing the risk of a crash or injury.
Remedy: Dealers will inspect the connection between the driveshaft and rear axle differential, and apply adhesive or replace the driveshaft and rear axle differential, as necessary, free of charge. Owner notification letters are expected to be mailed October 2, 2026. Owners may contact BMW customer service at 1-800-525-7417. Vehicle Identification Numbers (VINs) involved in this recall will become searchable on NHTSA.gov beginning October 2, 2026.
- NHTSA 21V554000Jul 21, 2021Seat Belts21,537 vehicles
Seat belts
BMW of North America, LLC (BMW) is recalling certain 2021 2 Series (230i, 230i xDrive, M240i, M240i xDrive), 330e, 330e Xdrive, 4 Series Coupe (430i, 430i xDrive, M440i xDrive) M4 Coupe, M4 Competition Coupe, BMW 4 Series Convertible (430i, M440i), BMW X1 sDrive28i, xDrive28i, 2 Series Gran Coupe (228i, 228i xDrive, M235i xDrive), M2 Competition Coupe, 330i, 330i xDrive, M340i, M340i xDrive, M3, M3 Competition, 530i, 530i xDrive, 540i, 540i xDrive, MINI Hardtop 2 Door (Cooper, CooperS, JCW), X2 sDrive28i, X2 xDrive28i, X2 M35i, Z4 sDrive30i, Z4 M40i, MINI Hardtop 2 Door (Cooper SE), MINI Convertible (Cooper, Cooper S, JCW), MINI Clubman (Cooper S, Cooper S All4, JCW), MINI Countryman (Cooper, Cooper All4, Cooper S, Cooper S All4, JCW All4), Rolls Royce Ghost, MINI Countryman (Cooper S E All4), Rolls Royce Phantom, Rolls Royce Cullinan, and Toyota Supra vehicles. The passenger seat belt Automatic Locking Retractor (ALR) may deactivate early, before the webbing fully retracts. As such, these assemblies fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 208, "Occupant Crash Protection."
Risk: During a crash, a seat belt retractor that does not function as intended increases the risk of injury.
Remedy: Dealers will inspect the seat belt retractors (including the seat belts) and, if necessary, replace the retractors, free of charge. Owner notification letters were mailed on September 3, 2021. Owners may contact BMW customer service at 1-800-525-7417; 1-866-825-1525 (MINI); 1-877-877-3735 (Rolls Royce); and 1-888-270-9371 (Toyota).
- NHTSA 21V096000Feb 19, 2021Collision Avoidance & Cameras13,858 vehicles
Back over prevention:software
BMW of North America, LLC (BMW) is recalling certain 2019-2021 X3 sDrive30i, X3 xDrive30i, X3 M40i, X3M, X4 xDrive30i, X4 M40i, M550i, X4M, X5 sDrive40i, X5 xDrive40i, X5 xDrive50i, X5M, X5 M50i, X7 xDrive40i, X7 xDrive50i, X7 M50i, Alpina XB7, 330i, 330i xDrive, M340i, M340i xDrive, and 8 Series Coupe, Convertible and Grand Coupe, 840i, 840i xDrive, M850i xDrive, M8, 2020-2021 530e, 530e xDrive, 330e, 330e xDrive, 745Le, 745Le xDrive, X5 xDrive45e, X3 xDrive30e, X6 sDrive40i, X6 xDrive40i, X6 xDrive50i, X6 M50i, X6M, 530i, 530i xDrive, 540i, 540i xDrive, M550i xDrive, M5, 740i, 740Li, 740Li xDrive, M760i Drive, M760Li xDrive, 750Li xDrive Alpina, Alpina B7 xDrive, and 2021 4 Series Coupe 430i, 430i xDrive, M440i xDrive vehicles. When shifting into Reverse, a small portion of the rearview image may be obscured, or the screen may not illuminate. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 111, "Rear Visibility."
Risk: If the driver relies on only the rearview camera image, the missing or reduced rearview image view can increase the risk of a crash or injury.
Remedy: BMW will notify owners, and dealers will inspect the rearview camera software and update it if necessary, free of charge. The recall began April 16, 2021. Owners may contact BMW customer service at 1-800-525-7417.
2021 BMW 540i fuel economy and fuel cost
- City
- 24 MPG
- Highway
- 31.5 MPG
- Combined
- 26.5 MPG
- Annual fuel cost (EPA)
- $3,000
- 15,000 mi/yr
- Fuel
- Premium
- Current regular gas
- $4.32/gal
- national avg.
EPA figures; median across configurations of this model year. Estimate your own cost with the fuel cost calculator.
2021 compared with other 540i years
Frequently asked questions
- Is the 2021 BMW 540i reliable?
- NHTSA data gives the 2021 540i a complaint index of 38, the 6th worst of 9 model years tracked, and it carries a Good verdict relative to other 540i years.
- What are the most common problems with the 2021 BMW 540i?
- Brakes and Transmission & Powertrain are the top problem areas, each making up 33% of the 9 complaints filed, followed by Electrical System issues at 22%.
- Does the 2021 BMW 540i have any recalls?
- NHTSA lists 6 recall campaigns for the 2021 540i, covering the transmission/driveshaft connection, seat belt retractors, rearview camera software, output shafts, and a 48-Volt battery connection issue.
- How does the 2021 540i compare to other model years?
- Its complaint index of 38 is lower than the 2018 (100), 2022 (88), and 2023 (75) model years, all rated Avoid, making 2021 one of the better years for the 540i.
- At what mileage do 2021 540i problems typically appear?
- NHTSA data shows a median mileage of 38,350 across all reported failures, with transmission/powertrain complaints specifically averaging 66,700 miles.