I have a 04 545i with active sway bars and active steering. last week while I was driving home I noticed a clunk that got worse as I got down the road. Then I noticed a rubbing/ grinding sound when I turn to the right at speed. No rubbing/ grinding sound at very low speeds while turning right. No rubbing / grinding while turning left at speed and at slow speeds just clunking.

Got home jacked the car off and started to shake things . Got to the sway bar and saw the whole driver side bracket broken off at the bottom weld. Wtf!!! How does that happen. Called BMW North America and they said there is no recall but they have heard of this issue. Talked to an Indy and they advised they have seen this and sent the car to someone who welds aluminum. The weld only lasted a few months before breaking again.

I will be dropping off the car at the dealer Friday to see if this can be recalled or fixed due to a defect or something. Any other suggestions. If they don't fix it I will not be paying over 2k for them to put in new engine cradle. I guess I'll be trying to find someone that welds.

Question is should I find someone to weld it? What's causing the grinding rubbing sound? Is it the active sway bar motor?

Thanks

 

Seen it myself several times. I believe member HealthServices also had this happen or fixed someone that had this happen.

 

Yessir, Healthservices had this happen to him. I would send him a message, he is pretty responsive. He welded his back together himself, but he's got skills like that. It's aluminum and from what I remember pretty flimsy (BMW could've made it a little stronger with some bracing behind he plate that sticks down. Good luck

 

Its time we start a Recall Class action. Same here. Welded it first time then it broke again right after I had new front struts installed... $2K. Dealer wants over a $1,000 for the sub frame and sway bar. 9 hours at indy shop its going to be over $2K. I called it a road hazzard and we're in discussion with the insurance company.

I don't think this was engineered well and when the next one snaps in 5 years, I'm filing a lawsuit against BMW or they can fix it for free.

 

I went thru the same issue , but would say it was my fault for hitting a curb on a narrow drive way .. But I went out and bought a piece of aluminum made an exact duplicate of the bracket .. Had my friend thats a certified pipe line welder weld it .. Its been several years since and its held up great , Ive had no issues with the repair .

 

Hey....been doing research on this problem and seems like a common fault. I have a 2007 550i and the driver's side active sway bar bracket detached from the bottom weld. It's still in place with the upper bolt holding. My attempt on finding an aluminum welder has not been successful. They all tell me that they don't want to risk TIG welding on the vehicle which means I have to remove the subframe for them to do it. The risk of fire and shorting out the computers or electronics is the concern. Did you have it welded while on the car? If so, what was the cost? What is the labor cost on replacing the subframe if anyone knows? Thanks

 

As long as you disconnect the battery you should be OK while welding on the car, body shops do it all the time. Heck, I even see a lot of body shops weld on cars with the battery still connected.

 

Well, I hope to find an aluminum welder that is willing to take the risk. I'd like to take care of it before it gets worse. I might have to replace the whole subframe and reinforce that mounting point before the install. I wonder what that would cost?