NHTSA Complaint #10899649 — 2008 BMW 528I

HAD TO REPLACE A HEADLIGHT BULB AND A TURN SIGNAL BULB. WHEN OPENING THE HEADLIGHT ASSEMBLY TO ACCESS THE TWO BULBS MUCH OF THE INSULATION ON THE WIRING INSIDE THE HEADLIGHT ASSEMBLY JUST CRUMBLED AWAY INTO VERY TINY PIECES AND DUST, WHICH FELL INTO THE BOTTOM OF THE ASSEMBLY. IT'S AS IF THE WIRE INSULATION HAS DRIED OUT AND FAILED IN THE EIGHT YEARS SINCE THE CAR WAS MANUFACTURED. NOW MOST OF THE WIRING IS JUST BARE AND EXPOSED. THE WIRING CAN'T BE ACCESSED FROM OUTSIDE AND THE HEADLIGHT ASSEMBLY DOES NOT COME APART. I AM VERY CONCERNED ABOUT THE WIRING SHORT CIRCUITING AND POSSIBLY CAUSING A FIRE IN THE HEADLIGHTS. I'M 68 YEARS AND HAVE OWNED 13 DIFFERENT CARS FROM AMERICAN AND GERMAN MANUFACTURERS. I HAVE NEVER ENCOUNTERED ANYTHING LIKE THIS. I THINK THERE IS A MANUFACTURING DEFECT IN THE HEADLIGHT ASSEMBLY WIRING. I CONTACTED BMW ABOUT THIS AND THEY WOULD NOT DO ANYTHING ABOUT THIS PROBLEM. I THINK THIS MAY BE A SIGNIFICANT DEFECT THAT COULD AFFECT THE SAFETY OF THE CAR. I HAVE DONE SOME SEARCHING ON THE INTERNET AND HAVE FOUND THAT THIS IS A VERY COMMON PROBLEM IN THIS SERIES OF BMW CARS. BMW WON'T AKNOWLEDGE A PROBLEM AND WON'T PROVIDE ANY ASSISTANCE OTHER THAN TO SUGGEST THAT I BUY NEW HEADLIGHT ASSEMBLIES FROM THEM WHICH WERE MADE WITH THE SAME POOR QUALITY WIRING.