the taillight, blinker and reverse light all went out and when I pulled the components out To check to see if the bulbs are burnt all of the bulbs are perfectly fine, but the aluminum pieces were sparking, and the whole component will not work

- Mitchell, SD, USA

Station wagon lift gate has severe wiring failures between the lift gate and body. This problem is well known throught the blog community. Broken wires cause failures, and electrical danger, to the rear lighting system that includes brake, running, back up, and turn signals. Also effected is the rear wiper, defroster, and operation access to open and close the lift gate. Tailgate failure would prohibit emergency opening and access to spare tire and fuses. I have already spent $3,000 on one harness replacement (dealer) and am looking at another $3,000 to repair (dealer) more wiring that will restore the brake/running lights on one side (failed state inpection). The internal lighting diagnostics did NOT indicate any lighting problems or warning. Broken wires could also cause failures to some or all of the entire electrical system. Very dangerous.

- Richmond, VA, USA

Known safety concern due to broken wiring in E61 wagon hatch wiring. See this thread: Https://5series.net/forums/E61-touring-discussion-4/tailgate-wiring-harness-replacement-72751/

- Fremont, CA, USA

Insulation crumbling on all wiring inside both headlight (driver and passenger sides) units resulting in malfunctioning headlights, running lights, and marker lights. Unfortunately, a common problem and a huge safety concern. Issue is exacerbated but not caused by heat. Insulation on wiring to navigation, radio/media player, climate control unit, or ccc (car communication computer), crumbling causing malfunctions to occur in all the above sections. I suspect much of the car's wiring to be in similar, poor condition. I have read that many european cars from the '80S, '90S through the first ten or so years of the 21st century used a soy based, biodegradable wire insulation as part of a "green movement". this early implementation of said wire does not last much longer than 10 years, much less than that when exposed to heat. Please see: Https://www.bimmerforums.com/forum/showthread.php?2132684-headlight-wire-jackets-just-flake-off https://5series.net/forums/E60-discussion-2/headlight-wiring-outer-jacket-deteriorating-139655/ www.peachparts.com/shopforum/off-topic-discussion/330631-can-you-believe-BMW-still-using-biodegradeable-wiring-insulation.html www.mercedesdefects.com/2008/04/wire-harness-defect.html https://rennlist.com/forums/Porsche-cayenne-forum/733521-brittle-wiring-insulation.html there are many, many more threads such as these on the web. There are thousands of cars on the road like this. The manufacturers keep producing vehicles with this type of wiring. It's wonderful that the insulation degrades. It's absurd to start biodegrading when the car is just five or so years old.

- Moncks Corner, SC, USA

The wire insulation inside the headlamp housing becomes brittle and can short out. They can flicker or go out. If both left and right experience a short, a driver can be left driving at night without headlights. This can result in deadly accidents. This has happened to my rh headlight. The issue has long been known and complaints are posted all over BMW forums. Replacement headlamps are in excess of us$900 each leaving many car owners to go with defective headlamps. I was driving my car tonight when the rh lamp went out for a few moments due to the wiring short. I can only imagine how it would have been if both went out. I don't have photos or video evidence.

- Collierville, TN, USA

Wire insulation inside the headlight housing is falling away leaving bare wires. Currently only affecting the drl. Searching BMW forums - this is not an uncommon problem. This is a dangerous condition being that the headlights could fail at any time. Replacement is prohibitively expensive at more than $700 per unit. With the number of complaints that I have seen in on-line forums, I feel this should warrant a safety related re-call. Thank you in advance for your time.

- Birmingham, AL, USA

I have a 2008 535I (E60) w/55K miles, in otherwise perfect condition with no aftermarket alterations. While driving car in the highway, I had a parking light alert/error that my parking light was out. After arriving to my home I inspected my headlight assembly. The angel eyes on both left and right headlight showed completely bare wires on both sides of the bulb connectors, on both sides of the car. I found flaking insulation and bare wires everywhere the inner sealed headlamp assembly!!!. the more I touched the wires, the more insulation flaked off, almost like a powder. I've never seen anything like it. Definitely a fire hazard!!!!

- Morovis, PR, USA

I ordered new light bulbs to change out my halo angel bulb lights (running parking lamps).which said they were out on my screen inside of the BMW. When I twisted off the housing cap in the back, the wiring inside of my headlight housing which turns on my parking lights left and right is totally degraded and flaked off, the copper cables were touching everywhere.I read this is because germany use biodegradable material but this is a very dangerous fire hazard for driving on the highways and road in Florida. We as 5 series owners for these years need a recall of new harness with better wiring.even if you buy a new housing it will do the same thing in 4 years guaranteed. You would have to find some one to rewire it with the same cables Ford uses so it can last 20+ years. Please fix.

- Sunny Isles, FL, USA

My 2008 BMW 535I headlight went out and I took it to a certified mechanic to change the headlight bulb, he took out the headlight and shown to me the wiring in both headlights have flaked off and had presented a fire hazard situation which caused the fuse the blew. I researched the BMW forums and found lots of people with the same issue, hence, it is not an outlier. I contacted BMW usa and they refused to remedy the situation. I was told by them that the vehicle is out of warranty and that the vehicle mileage was past the headlight wiring should not go bad in 8 years and they were rude and told me they will not pay for it. I also learnt that most of these headlight wires in the E60 flaked off within 50K miles and are not discovered until a short or blown bulb. Hella (the manufacturer of the headlight) said it is not their problem since the make the headlights to BMW specifications.

- Lawrenceville, GA, USA

Wires inside headlights have insulation crumbling off. Fire risk. So many BMW's have this problem. A clear issue that BMW knows about.

- Houston, TX, USA

Wiring for daytime running light melted all wiring insulation off. I got a shock while replacing the bulb before I realized there was no insulation left. To replace the light fixure it is in excess of $1,500 each and both have all insulation melted off their wires. The bulbs do not stay on and we're having difficulty getting a valid nh inspection sticker.

- Somersworth, NH, USA

Fraud activity possible clone refinanced identity theft remote access was put on unauthorized threat safety for owner. Two loan start dates one in repo

- Ft Worth, TX, USA

Just bought a used 2008 528I (E60) w/94K miles, in otherwise perfect condition. Went to change the angel eyes from drab yellow to lux led's. noticed bare wires on both sides of the bulb connectors, on both sides of the car. Tried to use electrical tape, just made more bare wire. The more I touched the wires, the more insulation flaked off, almost like a powder. I've never seen anything like it. Can't possibly be safe. Definitely a fire hazard. Neighbor brought over a bottle of liquid tape, and I re-coated all the bare wire I could see, making sure each wire was separated so a short would not occur. That is a good temporary fix. Will have to stay on top of this problem, since most, if not all, of the headlight wiring is made with bad, quickly degrading wire insulation. A real disappointment in otherwise good german quality and engineering. I guess the source procurer at the factory saved BMW some big bucks on that wire!! this is definitely a NHTSA safety recall issue. Tort lawyers should have a field day on this one. Photos of this problem are available at: www.bimmerforums.com/forum/showthread.php?2132684-headlight-wire-jackets-just-flake-off

- Canyon Lake, TX, USA

Electrical wiring insulation/sheathing within the headlight unit/housing is showing signs of and or outright deterioration which in turn exposes bare wires within the headlight housing. At this point, the daytime running lamps have been the only effected lights but the wires for the headlights are also noticeably troubled. The issue is not speed, movement or area dependent. For further reference, I will provide a link to an owner's forum detailing other's dilemmas due to this exact issue: www.bimmerfest.com/forums/showthread.php?T=798640 I look forward to a response.

- Kingsville, TX, USA

The head light wiring has flaked off and caused a shortage in my headlights.

- Lauderdale Lakes, FL, USA

Right rear hatchback running light shuts off when hatch shuts or is fully open, but comes on when in between fully open and completely closed.

- South Burlington, VT, USA

Headlight almost caught on fire. Started car and as I was backing out of garage I smelled a burning smell and then received a drivers side bulb out error indication. When I returned to the house I looked at the headlight and noticed the inner lens had fallen away inside the housing. I began to examine the headlight closer and discovered a lot of wires that were basically rotten. Meaning there was no insulation what so ever to protect against a short if the wires made contact. I examined the passenger side headlight only to find the exact same condition with the wiring, large amounts of bare unprotected wires. Further investigation showed the entire inner lens became so hot that the plastic welds melted and also the metal housing causing the lens to fall away. I contacted BMW na and was told on the phone they were aware of the problem but could not cover the repair because the car is out of warranty. This situation could have easily led to a full vehicle fire had I not inspected the problem and attempted to repair with electrical tape. I cannot get to all of the bare wires because they are inside the head light. The cost of replacing both headlight is ~ $3000 parts plus around 250 in labor charges. Sadly if this is not properly discovered it could lead to a total destruction from a fire in the vehicle and even death if the driver was to become a asphyxiated from the fumes while traveling on the highway.

- Simpsonville , SC, USA

The insulation of the wiring inside the headlight assembly is crumbling and poses a fire hazard as the wires have lost their insulation and can get in contact with each other.

- Fremont, CA, USA

E61 wagon, rear hatch: I discovered failures of multiple wires in the tailgate/rear window wiring harnesses. Through research online I have found this is a common problem with this vehicle over several model years - search for BMW E61 tailgate wiring problems. The failures are caused by a poor design where the wires entering the hinge guides (4) for the glass and tailgate are repeatedly flexed at a sharp angle until the insulation, then the copper wire breaks. Safety issues - possible electrical short circuit leading to fires (highest load is for rear defroster); lighting failures (rear high brake light, license plate lamps and others); reduced visibility due to loss of wiper/washer/defroster; rear glass latch opening while underway, possibly resulting in loss of cargo or ingress of exhaust fumes. This is not an easily repaired problem. It would be beyond the capabilities of all but a skilled mechanic with proper tools. I discovered it when the remote lock/unlock using the key fobs failed. As I investigated I found the broken wire, along with several others with broken insulation, some with broken copper strands.

- Seattle, WA, USA

The contact owns a 2008 BMW 535I. The contact stated that while driving approximately 55 mph, the rear driver's side brakes failed accompanied by the illumination of the warning indicators. The failure was recurring. The contact referenced NHTSA campaign number: 13V407000 (exterior lighting) but did not confirm if the vehicle was included in the recall. The manufacturer was made aware of the failure. The vehicle was not taken to the dealer or an independent mechanic. The vehicle was not repaired. The approximate failure mileage was 98,000.

- Burlington , NC, USA