NHTSA Complaint #10349331 — 2002 BMW 540I

1. EVENTS LEADING UP TO FAILURE: I DROVE THE CAR 5MIN AND PARKED FOR 30 MINUTE LUNCH. WHEN I STARTED THE CAR, THE POWER STEERING FAILED IMMEDIATELY AND I COULDN'T TURN THE WHEEL. 2. THE FAILURE, FREQUENCY, CONSEQUENCES: POWER STEERING PUMP MOUNTING BRACKETS FRACTURED NEAR THE BOLTS THAT RETAIN THE PART TO THE CHASSIS. THE PUMP SWUNG LOOSE, ALLOWING THE BELT TO JUMP. THE TENSIONER PULLEYS WERE DAMAGED. MY MECHANIC IS UNAWARE OF OTHER INCIDENCES, THOUGH I FOUND DOCUMENTED REPORTS OF THE SAME FAILURE WITH PHOTOS AT THIS SITE: HTTP://WWW.BIMMERFEST.COM/FORUMS/SHOWTHREAD.PHP?T=323318 FORTUNATELY, THIS STEERING FAILURE HAPPENED AT NO SPEED. IF I HAD BEEN DRIVING, THE FAILURE COULD CAUSE LOSS OF STEERING, WHICH WOULD BE ESPECIALLY DANGEROUS BEFORE A TURN ON A MOUNTAIN ROAD. I COMMUTE IN THE MOUNTAINS DAILY. 3. WHAT WAS DONE TO CORRECT THE FAILURE LABOR SERVICE - ORIGINAL CHECKOUT 73.00 BELTS CAME OFF PULLEYS: BELTS CAME OFF PULLEYS: THE POWER STEERING PUMP BROKE LOOSE FROM ITS MOUNTING TABS. THE POWER STEERING SUPPLY AND RETURN HOSES ARE LEAKING, THE FAN BELTS ARE DAMAGED ,AND THE FAN BELT TENSIONER PULLEYS ARE NOISY. RECOMMEND TO REPLACE THESE ITEMS. SEE QUOTE BELOW. LABOR SERVICE - POWER STEERING PUMP 1,093.00 LABOR SERVICE - POWER STEERING SUPPLY AND RETURN HOSES AND FLUID FLUSH 534.00 LABOR SERVICE - FAN BELTS 280.00 LABOR SERVICE - TENSIONER PULLEYS 618.00. *TR