NHTSA Complaint #10577907 — 2003 BMW 3 SERIES

BMW DID NOT PROPERLY DESIGN THE REAR FLOOR OF THE CAR BODY WHERE IT SUPPORTS THE REAR SUBFRAME. AS A RESULT UNDER NORMAL DRIVING, MANY OF THE BMW E46 3-SERIES CARS (325, 323, 330, IN THE I, CI, OR CIC TRIMS, EXAMPLE 325CI OR 330I) SUFFER FROM TORN SHEET METAL WHERE THE REAR SUBFRAME ATTACHES TO THE BODY. THIS EVENTUALLY CAUSES A MAJOR SAFETY HAZARD AS THE REAR SUBFRAME AND ASSOCIATED SUSPENSION CAN SEPARATELY ENTIRELY FROM THE VEHICLE RESULTING IN A LOSS OF CONTROL AND SEVERE CRASH. THIS CAN AFFECT ANY E46 3-SERIES CAR BUT IS MOST COMMON IN MODELS BUILT FROM 1999-2001 AND MORE COMMON IN MANUAL TRANSMISSION CARS. THE REPAIR COSTS ANYWHERE FROM $800 (PRE-EMPTIVE STRENGTHENING OF SHEET METAL IF IT HAS NOT TORN ALREADY) TO $5,000 (REPLACEMENT OF REAR BODY SUBFLOOR). BMW SETTLED A CLASS-ACTION LAWSUIT IN 2009 ALLOWING 3-SERIES OWNERS TO HAVE THEIR CARS INSPECTED AND IN SOME CASES REPAIRED BY BMW BUT THIS DID NOT COVER ALL AFFECTED CARS AND EXPIRED IN DECEMBER 2010 SO NOT ALL OWNERS WERE ABLE TO HAVE THEIR CARS INSPECTED OR REPAIRED BY THAT DATE. IN ADDITION MANY CARS HAVE EXPERIENCED SUBFRAME MOUNTING FAILURES AFTER DEC 2010. BMW SHOULD BE REQUIRED TO INSPECT, REPAIR, AND REINFORCE ALL E46 (1999-2005) 3-SERIES BODIES WHERE THE REAR SUBFRAME MOUNTS. *TR