NHTSA Complaint #10167196 — 2000 BMW 328IC

THE REAR SUBFRAME MOUNT IN MY 2000 328CI HAS A SIGNIFICANT FATIGUE CRACK AT THE SUBFRAME MOUNT WITHIN THE REAR AXLE SUPPORT. THIS PART, BMW #41117000246, FAILS DUE TO FATIGUE CRACKS FORMING IN THE SHEET METAL AT THE PERIPHERY OF THE SPOT WELDS OF THE SUBFRAME MOUNT TO THE BODY OF THE CAR. THE CRACK WAS OBSERVED DURING A REGULAR INSPECTION OF THE VEHICLE. THIS IS A SERIOUS AND MORE COMMON FAILURE THAN THE NUMBERS REPORTED TO NHTSA. ONE ENTHUSIASTS SITE HAS A LIST WITH 120 1999 AND 2000 E46 CARS WITH THIS FAILURE. THE CRACK IN MY CAR WAS OBSERVED BECAUSE I KNEW TO LOOK FOR IT. OTHERS HAVE NO IDEA THAT THIS WILL HAPPEN. THERE WAS NO PRIOR ACCIDENT OR EVENT THAT WOULD MAKE ONE SUSPECT SUCH A FAILURE. I ONLY KNEW BECAUSE A FELLOW BMW CAR CLUB MEMBER WARNED ME TO LOOK. THE CONSEQUENCES IS THAT THE REAR DRIVETRAIN AND SUSPENSION ARE SEPARATING FROM THE BODY OF THE CAR. AFTER THE FIRST SUBFRAME MOUNTING POINT FAILS (VIRTUALLY ALWAYS ON THE DRIVERS SIDE REAR) THEN THE PASSENGER SIDE REAR FAILS. IF SOMEONE FAILS TO FEEL THE WOBBLY FEEL TO THE DRIVETRAIN AND SUSPENSION THE FRONT TWO MOUNTS (4 TOTAL IN THE BACK) WILL PROCEED TO RIP OUT. NEXT THE UPPER SHOCK MOUNTS FAIL. AT THIS POINT THE CONNECTION BETWEEN THE CAR AND SUSPENSION/DRIVETRAIN IS VERY DANGEROUS. THERE ARE FIXES FOR THIS BUT THEY INVOLVE REMOVING THE ENTIRE REAR AXLE SUPPORT WHICH IS A VERY INVOLVED PROCESS AND COSTS > $4000. BMW CHANGED THIS DESIGN IN 2001, BUT HAS DONE NOTHING TO ADDRESS THE E46 CARS PRODUCED BEFORE THEN. THIS IS DANGEROUS AND COULD BE ADDRESSED FOR SIGNIFICANTLY LESS MONEY IF DONE BEFORE CRACKING STARTS. BMWAG REPAIRED OR REINFORCED ALL E46 CARS PRODUCED PRIOR TO FEBRUARY 2000, BUT BMWNA REFUSES TO. PLEASE LOOK INTO THIS AS THIS IS NOT RIGHT. *JB