Driver side headlight went out, so I automatically assumed that the bull was blown. Went and bought $100 bull that controls the high beam and the low beams, replace the bulb, and the headlight still doesn't work. Took the ball back and got another bulb, and the headlight still doesn't work. As I was replacing the bulb I noticed bare wires showing, on multiple wires, as far as I could see. This is definitely a safety issue, as it could cause my car to catch fire.

- Pelham, AL, USA

When I attempted to install new low beam, high beam, and angel eye bulbs I discovered that all the protective coating on the wires inside the headlight assembly was missing or crumbling off. These exposed wires are a certain fire hazard. Any attempt to repair the wire coating resulted in more coating crumbling off, exposing yet more of the wire.

- Timmonsville, SC, USA

Headlight wiring inside headlight assembly is deteriorating badly. The protective coating is cracking and flaking off leaving the exposed copper core which in turn shorts out the lights. Possible fire hazard as well.

- Hanahan, SC, USA

Replaced headlight bulb, passenger side, for the second time, within the past year, and about the fifth time (driver side and passenger side; headlight bulb and angel eye bulb) since we have owned the vehicle (purchased certified pre-owned from a BMW dealership, houston, tx). And the cause of the problem is inferior wiring insulation. The wiring insulation is deteriorating causing the bulbs to prematurely burn out and a possible fire hazard. The replacement bulbs are purchased from a local BMW store. They are not non-oem bulbs and they are not cheap. BMW needs to replace the entire headlight unit.

- Houston, TX, USA

Headlights.... angel eyes both sides burned off problem with electric sockets I would think!!! this is happening too a lot of BMW as reserch!

- Las Vegas, NV, USA

Low beam and fog light malfunction. I'm not a mechanic, but it looks to me like the casing around the wires is just disintegrating and may be arching. I tried electrical tape to try to insulate them, but to no avail. I've never seen such a thing happen. After looking around for recalls, I found no recalls on this subject, but found plenty of complaints about it. The malfunction is not constant, but is about 90% of the time. I have learned a way around it by moving the headlight dial to a different position. I'm due for an oil change now, so will have the dealer check it now that I'm going in for something else. But I'm guessing I'm going to be stuck with a hefty repair bill for something that was a design flaw.

- Jacksonville Beach, FL, USA

Headlight wiring insulation is flaking off and leaving exposed, uninsulated wires which can short out and cause malfunctions in the headlights, turn signals, parking lights, and daytime running lights.

- Orlando, FL, USA

I purchased a used 2008 BMW 528I mid-January of 2017. It was well maintained, a single owner vehicle with just over 60K miles. It has a clean carfax and a well documented history of regular maintenance at a BMW dealership in orlando, fl. After having the vehicle for just over 3 weeks, the passenger side day time running lamp went out. I received a "malfunction indicator lamp" (mil) on the dash so I investigated. Being at home and the vehicle in the garage, I removed the cover to the associated bulb, I noticed bare wiring that was associated with the plug-in connector (there are two wires). I thought this unusual and strange. I subsequently replaced the bulb but that did not repair the fault. Since the insulation on the faulty wiring was in contact with each other, it was providing a ground and shorting out the bulb. This could represent a potential for causing a fire and hazardous situation. Further research via the internet (forums), I was astounded at the amount of consumers who have expressed concern to BMW about this problem. Hella is the manufacturer of the headlight assembly for BMW. I am unsure at this time if BMW has expressed concern to hella of the potential liability associated with their substandard wiring in the headlight assembly. It appears over a 5-8 year period of use that the insulation is being subjected to high temperatures that cause brittleness, fractures and finally degrade to where the wiring becomes exposed. BMW is aware of this issue but does not appear concerned or motivated to resolve this problem. I am sure that there concerns revolve around profit margins, but I feel where safety is of concern, money should not be the reason for not correcting a problem. I respectfully request that investigation be conducted in order to discern the potential impact to consumers should this problem not be corrected by the manufacturer.

- Kingsland, GA, USA

Wiring inside headlight assemblies flaking off leaving bare wires.

- Moss Point, MS, USA

Headlamp wiring and connector has crumbled off leaving bare wires exposed and shorting out with possibility of causing fire.

- Winter Park, FL, USA

The vehicle is made with inferior wire coating that can and I'm sure has resulted in fires. Not to mention the features of the lights can and will stop working unexpectedly. This also causes shorts in the wiring of the switch in the dash I believe and possible battery drain leaving people stranded or even having car die while in motion. BMW had my car for 3 weeks trying to figure out all their other faulty issues - they finally had their head foreman take the car home with him and go over it with a fine tooth comb. He fixed most of the issues. They had sent me home with my car 3 or 4 times telling me my issues were resolved only for the car to stall, smell like burning rubber or just not start. They were also aware of the faulty wiring but did not list it as an item of eminent concern - however after taking car to another mechanic for a blown bulb a month later they expressed to me the extreme fire hazard the vehicle wiring posed and that because of the nature (or problematic design rather) of BMW they were not at Liberty to delve into such matters. BMW is the utmost morally reprehensible auto maker I have ever encountered from start to finish. My lights went out while driving and I was almost hit by a driver in a large escalade around dusk a week ago. What's worse is when I took vehicle to BMW I was also having them fix the tail light recall that is prone to cause fires. I have never met more incompetent people. You do not get what you pay for.

- Cooper City, FL, USA

Had to replace a headlight bulb and a turn signal bulb. When opening the headlight assembly to access the two bulbs much of the insulation on the wiring inside the headlight assembly just crumbled away into very tiny pieces and dust, which fell into the bottom of the assembly. It's as if the wire insulation has dried out and failed in the eight years since the car was manufactured. Now most of the wiring is just bare and exposed. The wiring can't be accessed from outside and the headlight assembly does not come apart. I am very concerned about the wiring short circuiting and possibly causing a fire in the headlights. I'm 68 years and have owned 13 different cars from american and german manufacturers. I have never encountered anything like this. I think there is a manufacturing defect in the headlight assembly wiring. I contacted BMW about this and they would not do anything about this problem. I think this may be a significant defect that could affect the safety of the car. I have done some searching on the internet and have found that this is a very common problem in this series of BMW cars. BMW won't aknowledge a problem and won't provide any assistance other than to suggest that I buy new headlight assemblies from them which were made with the same poor quality wiring.

- Phoenix, AZ, USA

Fraud activity possible clone refinanced identity theft remote access was put on unauthorized threat safety for owner. Two loan start dates one in repo

- Ft Worth, TX, USA

Just bought a used 2008 528I (E60) w/94K miles, in otherwise perfect condition. Went to change the angel eyes from drab yellow to lux led's. noticed bare wires on both sides of the bulb connectors, on both sides of the car. Tried to use electrical tape, just made more bare wire. The more I touched the wires, the more insulation flaked off, almost like a powder. I've never seen anything like it. Can't possibly be safe. Definitely a fire hazard. Neighbor brought over a bottle of liquid tape, and I re-coated all the bare wire I could see, making sure each wire was separated so a short would not occur. That is a good temporary fix. Will have to stay on top of this problem, since most, if not all, of the headlight wiring is made with bad, quickly degrading wire insulation. A real disappointment in otherwise good german quality and engineering. I guess the source procurer at the factory saved BMW some big bucks on that wire!! this is definitely a NHTSA safety recall issue. Tort lawyers should have a field day on this one. Photos of this problem are available at: www.bimmerforums.com/forum/showthread.php?2132684-headlight-wire-jackets-just-flake-off

- Canyon Lake, TX, USA

Insulation covering headlight wiring cracks off leaving large amounts of bare areas. This resulted in electrical shorts, draining battery, erratic electrical system behavior, blown headlight bulbs, and an intermittent burning smell in my car.

- Gulfport, MS, USA

Electrical wiring insulation/sheathing within the headlight unit/housing is showing signs of and or outright deterioration which in turn exposes bare wires within the headlight housing. At this point, the daytime running lamps have been the only effected lights but the wires for the headlights are also noticeably troubled. The issue is not speed, movement or area dependent. For further reference, I will provide a link to an owner's forum detailing other's dilemmas due to this exact issue: www.bimmerfest.com/forums/showthread.php?T=798640 I look forward to a response.

- Kingsville, TX, USA

Permanent loss of functionality of rear lamp functions tail, brake, turn-signal, reverse.

- Miami, FL, USA

Headlights: Wire insulation on head light cannon plugs is retracting from wires. This could cause an system electrical problem or fire.

- Mcdonough, GA, USA

Suddenly right sided headlight went out, I opened the headlight cover to change the bulb. Found all the wiring was crumbled and the coating was melted. Headlight came back on. Since then it happens a lot. I called bmwna to complaint about it and they said I have to open complaint with NHTSA. This has been reported by other BMW 528I 2008 owners. This is hazardous issue as open wires can potentially catch fire in headlight. Same problem in tail light initiated recall last year.

- Covington, LA, USA

The contact owns a 2008 BMW 528I. The contact stated that the inside of the headlight housing became abnormally foggy. The bulb also looked as if it was foggy and fractured. The vehicle was taken to the dealer, where the technician was unable to diagnose the failure. The manufacturer was notified of the possible default. The failure and current mileage was 106,000...updated 06/09/14 the consumer stated after replacing the headlight's bulb, it was found that all the cable insulation inside both headlights were crumbling. This could cause a fire or electric system failure. The dealer advised the consumer needed to replace the headlights. Updated 06/12/2014

- Miami, FL, USA