Transmission Final Drive Gear Improperly Welded – 2023 BMW iX M60 Hybrid

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October 5, 2022 NHTSA CAMPAIGN NUMBER: 22V741000

Transmission Final Drive Gear Improperly Welded

The gear weld seam could break, resulting in a vehicle rollaway if the parking brake is not applied, and increasing the risk of a crash.

 

NHTSA Campaign Number: 22V741

Manufacturer BMW of North America, LLC

Components ELECTRICAL SYSTEM

Potential Number of Units Affected 1

 

Summary

BMW of North America, LLC (BMW) is recalling one 2023 iX M60 hybrid electric vehicle. The transmission final drive gear in the electric drive unit may have an improperly manufactured weld seam.

 

Remedy

A dealer will replace the electric drive unit, free of charge. Interim owner notification letters informing owners of the safety risk were mailed on November 30, 2022. The owner notification letter is expected to be mailed November 28, 2022. Owners may contact BMW customer service at 1-800-525-7417.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.

 

Check if your BMW has a Recall

 


Service Information Bulletin

Electric Drives

October 17, 2022

Please perform the procedure outlined in this Service Information on all affected vehicles before customer delivery. In the event the customer has already taken delivery of the vehicle, please perform the procedure the next time the vehicle is in the shop.

 

RECALL 22V-741: REPLACING REAR DRIVE UNIT (HEAT)

 

MODEL

E-Series Model Description
I20 iX M60

 

AFFECTED VEHICLES

Vehicles which require this Recall to be completed will show it as “Open” when checked either in AIR, the “Service Menu” of DCSnet (Dealer Communication System), ISPA Next or Warranty Vehicle Inquiry.

 

SITUATION

It has been determined that a weld seam in the rear electric drive unit (HEAT XLR220) may not have been properly constructed.

 

CAUSE

In very rare cases, the weld seam may break due to strong acceleration. This is indicated by a sudden metallic noise from the rear drive area.  Continuous driving is only possible or recommended at restricted speed.

 

CORRECTION

Replacement of rear drive unit (HEAT XLR220).

 

PROCEDURE

Important Warning for Working on the High-Voltage (HV) systems on BMW Group vehicles:

Only properly trained personnel, who passed all applicable HV Technical Training Courses, should perform repairs which require disconnecting, or removal of High Voltage battery components on any Hybrid or Electric Vehicle. Work performed on High Voltage systems by unqualified persons may result in severe injury or damage to the vehicle. Additional safety information is found in Repair Instruction 61 00… “Observe safety instructions when handling electric vehicles”.

Additional Information:

Scheduled Maintenance, or Quality Certification 1 (Pre-Delivery Inspection) on Electric or Hybrid vehicles does not require HV technical training.

Prior to disconnecting, or the removal of any HV component, the HV system needs to be disabled and secured (by means of the HV Disconnect Switch) by a properly trained technician, who has a minimum HV Qualification level after completing the Technical Training Course ST1824 (Alternative Drive Part 1). Once the vehicle’s HV system is disabled (the “Blitz” – lightning bolt icon displayed in instrument cluster, see below), a technician without HV Certification may remove a HV component (e.g., EH Heater, EKK Compressor, EME Control Unit, et.), except for the High Voltage Battery.

High Voltage Battery removal and rework can be performed ONLY by a HV Specialist Technician (certified by the Technical Training Course ST1825 – Alternative Drive Part 2), AND with a HV Battery Certification level corresponding to a specific Electric or Hybrid vehicle (e.g., to repair GEN4 battery of G05 PHEV, certification from Technical Training Course “ST2006 – SP44 HV Battery” is required).

Replace the rear electric drive unit as per repair instructions 12 35 531 – Replace rear highly-integrated electric drive topology

 

PARTS INFORMATION

Note on parts availability: At the start of the technical campaign, only a very limited number of parts is available. For this reason, the existing parts will be allocated by the service centre according to respective market requirement. Provision of the parts can take several weeks.

Only use and invoice the applicable part listed number below.

Part Number (P/N) Description Quantity 
12 33 5A645E0 RP electric drive unit (220XLR) 1
33 17 6760336 Hexagon screw with washer (M14x1.5x133ZNS3) 4
33 32 6775040 Hexagon bolt with washer (M14x1.5×148) 4
61 27 9487464 Screw 4
33 13 1214961 Circlip (d=22.4) 2
33 30 6891268 Multi-purpose bolt 2
33 30 1544034 Eccentric screw (14×1.5×112 ZNS3) 2
33 55 6790913 Hexagon nut with collar (M10-10 ZNS3) 2
33 30 6861944 Hexagon bolt (M16x1.5×100) 2
07 11 9907136 Hexalobular socket screw (14×1.5×90-ZNS3) 2
34 20 6881294 BMW design clip 2
34 20 6850560 Hexagon bolt (M8X22) 4
07 14 6893779 ASA combination bolt (14×1.5×65 ZNS3) 4
31 20 6866022 Collar bolt with compression spring (M16x1.5×66) 2
07 12 9908011 Hexagon bolt with flange (M14x1.5×100) 2
33 30 6787062 Multi-purpose nut (M14x1.5-10ZNNIV) 2
07 14 8854416 Hexagon nut 6
33 30 6867271 Hex bolt (M14 x 1.5 x 84mm) rear suspension strut 2

 

Bulk Materials – Sublet

83 22 5A1D718 eFluid transmission oil (1 Liter) 1
83 19 2468442 HT-12 Coolant Sublet as needed

 


Chronology :

In late July 2022, during a dynamic driving test at a BMW assembly plant, a vehicle experienced an unusual noise when accelerating up a hill. An engineering review was initiated.

In August, initial reviews suggested that damage had occurred on the final drive gear of the transmission on the rear axle. Further analyses revealed that additional incidents had occurred to other vehicles during testing at the assembly plant. Analyses of these vehicles indicated that damage to the final drive gear had also occurred. A review of production records found that the final drive gears on these vehicles were produced during a specific production lot in late June.

On September 6, 2022, BMW decided to conduct a voluntary recall. At that time, all potentially affected US vehicles identified were within the control of BMW, were held at the US ports, and would receive an update prior to wholesale release into the US market.

Accordingly, on September 13th, BMW submitted a Part 579 report to which NHTSA assigned Foreign Recall ID 22F-152.

Subsequent to the submittal of the Part 579 report, further reviews suggested that one additional vehicle, already in the US market, could potentially be affected. Additional analyses were performed, and it was determined that this one additional vehicle was potentially affected. Therefore, it was determined that a Part 573 report would be necessary.

On September 28, 2022, BMW decided to conduct a voluntary safety recall.

BMW has not received any reports, nor is BMW otherwise aware, of any accidents or injuries that may be related to this issue.

 


1 Affected Product

Vehicle

MAKE MODEL YEAR
BMW IX 2023

 


6 Associated Documents

Recall Acknowledgement

RCAK-22V741-4346.pdf 645.15KB

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Defect Notice 573 Report

RCLRPT-22V741-1993.PDF 214.324KB

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Remedy Instructions and TSB

RCRIT-22V741-6022.pdf 190.173KB

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Manufacturer Notices(to Dealers,etc) – Service Information Bulletin re RECALL 22V-741: REPLACING REAR DRIVE UNIT (HEAT)

RCMN-22V741-3289.pdf 190.173KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-22V741-9677.pdf 627.788KB

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Recall Quarterly Report #1, 2022-4

RCLQRT-22V741-0375.PDF 211.131KB

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22V741&docType=RCL

 


 

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