2007 BMW 5 Series ELECTRICAL SYSTEM,EXTERIOR LIGHTING

BMW Headlight wiring on the 530 series is defective. Wire Insulation throughout the headlight assembly crumbles. The design and wire specification were not fit for use. Heat may be an issue but has nothing to do with climate. The vehicle has spent most of its life in Michigan where the problem was first noted when the age of the vehicle was approximately 8 years. High heat within the headlight assembly also caused deterioration of the covering on fiber optic cable. This problem is well known to BMW owners. The bare wires within the headlight housing pose a risk of electrical shorts and potentially fires.

Headlight wiring has disintegrated and making headlight short

HEADLIGHT WIRING INSULATION ROT LEAD TO FAILED HIGH AND LOW BEAMS ON DRIVER SIDE AND INTERMITTENT FAILURES OF BOTH BEAMS ON PASSENGER SIDE. SEE PHOTO FOR EXAMPOLE OF DISINTEGRATED WIRING ON DRIVER HIGH BEAM WIRING HARNESS. ONLY KNOWN OPTION IS TO BUY A COMPLETE NEW HEADLIGHT ASSEMBLY ($1250+ PER SIDE) OR ATTEMPT DIY. THIS PROBLEM IS WELL-KNOWN AND HAS LONG BEEN REPORTED BY OTHER BMW E60 (5 SERIES 2004-2010) OWNERS AT BIMMERFEST.COM AND 5SRIEST.NET. SEE THESE URLS FOR MORE INFORMATION: HTTPS://WWW.BIMMERFEST.COM/FORUMS/SHOWTHREAD.PHP?T=798640 HTTPS://WWW.BIMMERFEST.COM/FORUMS/SHOWTHREAD.PHP?T=883000 HTTPS://5SERIES.NET/FORUMS/E60-E61-PARTS-ACCESSORIES-MODS-22/OPENING-UP-E60-HEADLIGHTS-138473/

WAS REPLACING H7 HEADLAMPS AND DISCOVERED ALL OF THE INSULATION ON THE WIRING INSIDE BOTH HEADLIGHT ASSEMBLIES HAD DISINTEGRATED AND BOTH ASSEMBLIES CONTAINED MULTIPLE BARE WIRES. THIS COULD RESULT IN A SHORT OR BLOWING A FUSE WHEN DRIVING MAKING HEADLAMPS STOP WORKING. COULD EASILY CAUSE AN ACCIDENT. OR CAR COULD CATCH ON FIRE DUE TO SHORT CIRCUIT. I HAVE GOOGLED THIS AND FOUND MANY MANY SIMILAR COMPLAINTS. A RECALL SHOULD HAVE ALREADY BEEN VOLUNTARY ON BMW USA OR FORCED BY THE NTSB. EXTREMELY DANGEROUS SITUATION.

HEADLIGHTS INTERNAL WIRING GETA SO HOT IT MELTS AND CRACKS AND DETERIORATES AND CAUSES SHORT CIRCUIT EVENTUALLY LEADING TO BOTH OR SINGLE HIGH BEAM MALFUNCTION.

LH AND RH ADAPTIVE HEADLIGHTS WIRING INSULATION IS CRUMBLING POSSIBLY RESULTING IN A ELECTRICAL HEADLIGHT FIRE FROM THE EXPOSED BARE WIRES.

WENT TO REPLACE MY FRONT HEADLAMP BULBS AFTER HEADLAMP FAILURE WHILE OPERATING MY VEHICLE AT NIGHT, ON A WINDING ROAD, IN RURAL TEXAS. MECHANIC PULLED THE "SEALED" HOUSING, AND DISCOVERED THAT THE MAJORITY OF THE WIRES IN THE HEADLAMP ASSEMBLY HAD FAULTY INSULATION. THE INSULATION HAD "FLAKED" OFF TO THE POINT THAT MANY OF THE WIRES WERE EXPOSED, CAUSING A SHORT CIRCUIT, AND FAILURE OF THE HEADLAMP. RESEARCHED THE ISSUE ON MANY FORUMS, AND IT IS A COMMON OCCURRRENCE. REPLACEMENT COSTS OF EACH HEADLAMP ASSEMBLY IS APPROX $1500. THE USE OF SUBPAR INSULATION APPEARS TO BE THE CAUSE OF THIS SAFETY ISSUE.

THE LEFT FRONT PARKING BULB WAS NO WORKING, TOOK THE VEHICLE TO BMW DEALERSHIP IN COLUMBIA, S.C. TO HAVE BULB REPLACED. UPON PICKING UP THE VEHICLE, THE WARNING INDICATOR FOR THE SAME BULB AND THE LEFT FRONT HIGH BEAM WARNING BOTH LIGHTS WERE NOT FUNCTIONING CORRECTLY APPEARED. I RETURNED TO THE SERVICE DEPARTMENT TO INQUIRE WHY THE WARNING WAS ON, WHICH THEY STATED IT WAS PROBABLY LEFT LOOSE. THE SERVICE ADVISER RETURNED TO BRING ME INTO THE SHOP TO SHOW ME THE WIRING FOR THE LIGHT ASSEMBLY WAS CRACKING AND FALLING OFF, EXPOSING BARE WIRE CAUSING THE SHORT AND BLOWING THE BULBS. THE SERVICE DEPARTMENT AT BMW STATED A NEW ASSEMBLY WOULD BE REQUIRED WHICH WOULD BE ABOUT $1500 EACH FOR THE PARTS. AFTER REPLACEMENT OF THE BULB WHILE IN THE SERVICE DEPARTMENT, THERE WAS ANOTHER ELECTRICAL SHORT CAUSING THE BULBS TO BLOW IMMEDIATELY. I HAVE READ THE WIRING WAS COATED WITH A SOY BASED PRODUCT, WHICH IS WHY THE WIRING COATING IS PREMATURELY CRACKING AND EXPOSING BARE COPPER WIRE, CREATING AN ELECTRICAL AND FIRE HAZARD. DUE TO THE INADEQUATE MATERIAL UTILIZED BY THE MANUFACTURER, IT SHOULD BE RECTIFIED BY THE MANUFACTURER PRIOR TO SERIOUS INJURY OR DEATH.

REPLACING THE DAYTIME RUNNING LIGHT BULB THAT FAILED, I REMOVED THE HEADLIGHT ASSEMBLY FROM THE VEHICLE TO HAVE EASIER ACCESS TO THE BULB RECESSED DEEP INSIDE THE HEADLIGHT HOUSING. UPON OPENING THE ACCESS PANEL, I DISCOVERED THE WIRING INSULATION OF MOST OF THE INNER WIRING HARNESS OF HEADLIGHT BRITTLE AND FLAKING OFF, EXPOSING THE BARE WIRES. THE SHORT CIRCUIT PROBABILITY IS HIGH WITH THE EXPOSED WIRES IN CLOSE PROXIMITY.

I AM CONTACTING YOU IN AN ATTEMPT TO OBTAIN ASSISTANCE / REMEDY IN THE REPAIR OF A BURNED OUTER TAIL LAMP SOCKET IN MY 2007 530XIT. I AM THE ORIGINAL OWNER OF THIS VEHICLE. ON 12/31/2014 I RECEIVED A RIGHT TAIL LAMP MALFUNCTION WARNING VIA I-DRIVE AND WHEN I ARRIVED HOME I INSPECTED THE RIGHT TAIL LAMP ASSY AND FOUND THE OUTER TAIL LAMP BULB SOCKET CONTACTS TO BE MELTED AND NO LONGER MAKING CONTACT WITH THE BULB HOLDER. THE STOCK AND ORIGINAL BULB TESTED FAULTY. UNFORTUNATELY, DUE TO THE DAMAGED AND MELTED CONTACT ON THE SOCKET ASSY, THE BMW REPLACEMENT BULB WILL NOT FUNCTION EITHER. I HAVE A PHOTO OF THE SOCKET ASSY SHOULD IT BE NEEDED FOR INVESTIGATION. AS IS THE CASE WITH THE 2008-2010 E60 & E61 MODELS, THERE HAVE BEEN SUBSTANTIAL FAILURES IN THE REAR LIGHTING SYSTEM RESULTING IN A RECALL. I FEEL THAT THIS FAILURE REDUCES THE VEHICLES ABILITY TO WARN OTHER MOTORISTS OF THE DRIVER'S INTENTIONS, INCREASING THE RISK OF A CRASH AND SHOULD BE INVESTIGATED FOR A POTENTIAL RECALL ON PRE LCI E61 MODELS. *TR

ALL ACTIVE XENON HEADLIGHT WIRING PROTECTIVE COATING IS/HAS FLAKED OFF EXPOSING WIRES, MAKING IT VULNERABLE TO ELECTRICAL SHORT, LOSE OF DRIVING LIGHTS AND POTENTIAL FIRE HAZARD . *JS

THE SHEATHING ON MY HEADLIGHT'S WIRING IS FLAKING OFF WHICH COULD LEAD TO POTENTIAL FIRES. I WAS QUOTED $1500 PER HEADLIGHT TO REPLACE THEM WITH THE SAME CRAPPY HEADLIGHT HOUSINGS THAT ARE MADE WITH THE SAME MATERIAL THAT WILL EVENTUALLY DO THE SAME THING. ALL I NEED IS TO HAVE THE CAR PARKED IN MY GARAGE AND IT CAUSING A FIRE THAT COULD BURN DOWN OUR HOME OR WORST INJURE MY FAMILY. *TR

I WAS RECENTLY MADE AWARE THAT THERE IS A RECALL REGARDING THE REAR TAIL LIGHTS ON 2008+ 5 SERIES VEHICLES. I RECENTLY EXPEREINCED THE SAME SYMPTOMS AS THE RECALL NOTICE ON MY REAR TAIL LIGHTS; HOWEVER MY CAR IS A 2007 MODEL. THE I-DRIVE WOULD INTERMITTENLY ALERT THAT A BULB IS OUT. I HAVE REPLACED IT BUT IT WOULD GO OUT AGAIN. I INSPECTED THE BULB CARRIER AND BULB SOCKET AND NOTICED SEVERLY BURNED CONTACT AREA'S WHERE ONE OF THE BULB SOCKETS PLUG IN. THE RECALL CLEARLY IS FOR SEDANS 2008+ BUT I SEEM TO HAVE THE EXACT ISSUE AND THERE ARE OTHERS WHO HAVE THE SAME ISSUES (SEE 5SERIES.NET FORUM WEBSITE). *TR

THE HEADLIGHTS, DRIVING LIGHTS ARE ALL SHORTED OUT. THIS WAS A DANGEROUS SITUATION AS IT HAPPENED AT NIGHT. WHEN TAKEN TO MY MECHANIC, HE TOLD ME THAT IT IS A COMMON FAULT ON BMW'S. THAT THE WIRING FOR ALL THE LIGHTS IS MADE FROM RECYCLED PLASTIC AND WITH THE HEAT FROM OUTSIDE AND THE ENGINE THE INSULATION COMPLETELY DETERIORATES. HE SHOWED MY BARE WIRES EVERYWHERE AND IF YOU TOUCH THE INSULATION IT JUST CRUMBLES AWAY. HOW COULD A $55,000 CAR HAVE SUCH POOR WIRING THAT IS CAN CREATE A DANGEROUS AND POSSIBLY FATAL ACCIDENT. TO ME THERE SHOULD BE A COMPLETE RECALL OF AFFECTED VEHICLES.*JB