did anyone ever hear of stress fracture developing on the front windshield?
my car is 3 weeks old and developed a large crack around the rain sensor. there is always the possibility of it being caused by a rock, but???

Cracked windshields have occurred before. The experience of others in the forum has been that if a dealer can find any chip at all, it is not covered by warranty. Some allegedly have cracked wo any chipping. Good luck.

I had a stress crack on my 2004 530. Took it to the dealer, fixed under warranty.

Even if you have a chip in your window, you can demand that stress cracks be replaced. If the stress crack does not originate from the chip there is no reason for it to not be replaced. If they fight you then have a windshield expert look at it and back up your claim.

Remember (and remind the dealer) that this model has had extensive work done to the front portion of the frame to lighten the car. I've heard the window has also been made thin for weight saving. This could easily cause stress to the window and if you live in areas where there is a good range of hot to cold then even more chance for cracks.

My windshield had a crack in the lower driver's corner one week after I received the car, on a hot day, about 5 inches long. It actually happened while I was standing at a gas station filling up. The next day it became twice as long. The dealer replaced it on warranty, but had to order 3 (THREE!) times before they had the correct windshield -- then they forgot the molding clips which also needed to be replaced. :(