Driving on the freeway today and a mysterious crack formed on the lower left part of the front windshield. There was no noise or flashpoint. The dealer said they would replace it becuase they couldn't find an external cause. Only have 500 miles on my 2005 545i. Anything I should look out for on this repair? Anyone else have a problem like this?

 

Same lower left windshield crack, mine is being repaired under warranty on Monday.

 

I had mine repaired about a month ago...under warranty.

The service manager told me that mine was approximately the 5th one they'd had to replace. Evidently, the windshield's installation requirements are so demanding that it's easy to overstress them in the process of production. The crack begins in either side molding. Mine was on the right.

The repair is a 48 hour job, as the dealer is required to put tension on the glued windshield for that length of time before they can complete the installation.

 

I had the same problem on my 545 two months after delivery. Cracked started as a "L" shape and quickly spreaded the entire length of the windshield.

I was pretty bum out! :'(