[kaiv]

After about a month and half I finally got my car back just a couple of days ago.

I thought I'd share my story; I figure this is a common problem with the E46 and it might be of interest to many.

July 6: Apparition of the symptoms. Driving normally, the car feels very odd. Flat tire? No. Bad RTABs? No, they're new. I do my own maintenance.

I realize "it" happens under throttle. I give it more gas and the symptoms make themselves even more apparent: The rear end of the car would "squat" to the left, sending the front end to the right.

The more I accelerate the crazier it gets. Under heavy acceleration I have to correct my steering to the left my as much as 20 degres to keep going straight. As soon as I let of the gas the car straightens.

I deem the car unsafe and stop driving it. My car drove perfectly the day before.

A few days go by. I end up pulling the carpet in the trunk and I'm greeted by this:









"FML"

Back when I was car shopping I actually avoided the M coupe/roadsters just so that I never have to deal with this kind of BS. I didn't know the E46 M had those issues too.

An appointment is made with a local dealership.

July 17: I drop the car off at the dealer. I get assigned a goofball SA. I explain the symptoms, mention the crack.

A couple of days go by. The SA calls me back. They inspected the car. He tells me I need a new differential, and a rear alignment. $3k+. I have 3.91 Motorsport gears from TMS, I'm pretty sure my diff is fine. I decline the repairs and ask him about the crack. "What crack?" re-

Another couple of days go by. The SA calls back and explains that the rear frame of the car is tearing off.

He explains that there is absolutely nothing they can do other than referring me to a body shop. I try to get him to give me some info and I learn that there was a bulletin for this repair but it expired, he said.

Furthermore, I get the SA himself to say that he wouldn't drive the car, that the car is unsafe. Funny how he'd just send me on my merry way though. rerere-

I decide to just leave the car at the dealer for now.

July 23: I send an email to BMW NA; I explain everything. I also add that I'm a long time bimmerhead and express my dismay with the fact that the bulletin is supposedly expired. How is that fair to people who get the problem later on?

July 27: A get a call from a BMW NA rep. I'm told the bulletin is still active and that they will fix my car. Big relief!!

Now the thing is that the dealer cannot perform such repairs. They do mechanical stuff, not body stuff. They can't cut, they can't weld.

So they subcontract this kind of work to a specialist, a body shop.

I feel like this is why the dealer is so reluctant to take care of that problem. They get nothing out of it. The body shop does but not the dealership.

I believe I've read a couple of threads on here of people bringing their car in for a subframe inspection and be told they are OK; only to have an independent inspect it and find cracks.

Word of advice, have an independent BMW specialist double check if you can't spot cracks yourself.

July 30: My car makes it to the body shop that day. (It took a couple of days for the BMW NA rep and the dealership's service manager to synch).

From then on, since my SA isn't the brightest, I just get in contact directly with the body shop for updates and info.

August 5: I stop by the body shop. Some progress. The whole rear end is out, exhaust, driveshaft, rear subframe, suspension, gas tank, you name it it's off the car.

I chat for about 30 minutes with the body shop's owner and the tech in charge of my car. Real nice guys. I learn that they've done over 300 of those repairs. THREE HUNDRED!

Laying under my car is the brand new frame, or H-frame crossmember I believe they called it. They show me where they are going to cut and everything.

It's the part #16/1 on this diagram:



It's huge! FYI it can be found on RealOEM.com under bodywork> body-rear body.

Now my main concern was to know if the part is reinforced. If it's not then the problem is not solved and it's just a matter of time until it happens again.

Both the BMW NA rep and the guys at the body shop assured me that the part was redesigned and reinforced.

Furthermore, RealOEM.com actually shows two part numbers. One that was "ended" and another one replacing it.



So it's pretty safe to say that there is indeed a revised (and hopefully stronger) part

Everything is going well...and I get a call from the SA. "Your X5 is ready to picked up". Yet another "" worthy moment. Not wanting to make a fool out of him, I kindly explain that he must have his paperwork wrong etc.

Couple more days go by. I get a voicemail. It's the SA. My X5 is ready again. I'm laughing as I type this. This guy was a joke. I didn't bother getting back to him this time.

Anyway... Smooth sailing. In the end it takes a little longer for me to get the car back: I had the body shop pull out a couple of dents of the side.

August 17: I have the body shop on the phone and they are done with the car. It's being returned to the dealership where they will perform a 4 wheel alignment.

I call the dealership. I get the receptionist. Naturally, I ask for my SA... "I'm sorry sir, <insert SA name here> doesn't work with us anymore". I could hardly contain myself

August 19: My car is ready. I stop by the body shop to pay for having the dents pulled. I get a copy of BMW's invoice: it's 5 pages long with a grand total of $4000.

I stop by the dealership, they hand me the key and my invoice: $0.
(They did try to sell me some parts though )

Here's some pics I snapped of the new frame while installing my KW V2s:







There you have it. Oh and of course my diff is just fine. Boy am I happy to have my car back!

Cliffs:

*Failed frame symptoms resemble failed RTABs.
*Don't believe the $tealership. They'll quickly tell you you have some big $ item that needs replacement and/or misdiagnose.
*Have an independent BMW specialist double check your rear frame if you can't do it yourself.
*Lawsuit or not, there IS a bulletin, and BMW NA WILL take care of it.
*Bulletin includes new frame + 4 wheel alignment.
*The new frame is redesigned/reinforced.
*Thank you BMW NA for recognizing a design flaw and taking care of it like a real company.

[///M Dream]

Damn sounds like you went through alot man. Glad to hear it worked out and your car is back on the road

[benzthis]

i'm glad that there is a new reinforced subframe.with this hopefully there wont be any new tears.for those that said that bmw will never redesign the subframe floor,i guess you really dont know what you are talking about.to the op good job

[Muscle]

Crazy story, crappy SA :rofl:

Was the new and improved subframe ever installed on later models?

[greenhobby]

Wow, you have patience... Happy to hear your "whole" again!

-gh

[docwyte]

Did you have the Turner reinforcement plates added at the same time?

[m3freak86]

Wow, you really do have a lot of patience man. I would be going nuts if I were you. Glad to hear the problem is solved and everything is fixed up. BMW NA FTW!!!

BTW, that's hilarious about the SA that no longer works there lol

[deeboym3]

Originally Posted by kaiv

. "Your X5 is ready to picked up".

[Viper966]

why is the bottom of your car yellow, but the rest blue? including the inside of the trunk?

[statepkt]

Originally Posted by Muscle

Crazy story, crappy SA :rofl:

Was the new and improved subframe ever installed on later models?

would like to know as well