2021-2025 BMW 840I Starter Assembly Recall (25V644)
BMW of North America, LLC · 145,102 vehicles · Reported September 25, 2025
BMW of North America, LLC is recalling 145,102 2021-2022 BMW 740LI; 2021-2025 BMW 840I vehicles. After repeated attempts, the starter motor may overheat from an electrical overload. An overheated starter motor can ignite nearby combustible material in the engine compartment, increasing the risk of a fire. Dealers will make the repair free of charge.
Recall 25V644 at a glance
| NHTSA campaign number | 25V644000 |
|---|---|
| Manufacturer recall number | Not listed |
| Date reported to NHTSA | September 25, 2025 |
| Manufacturer | BMW of North America, LLC |
| Vehicles | 2021-2022 BMW 740LI; 2021-2025 BMW 840I |
| Units affected | 145,102 |
| Component | Electrical System > Starter Assembly |
| Safety risk | An overheated starter motor can ignite nearby combustible material in the engine compartment, increasing the risk of a fire. |
| Fix | Available at dealers |
What is wrong with the 2021-2025 BMW 840I in recall 25V644?
After repeated attempts, the starter motor may overheat from an electrical overload.
BMW of North America, LLC (BMW) is recalling certain 2020 340I, X6, 2020-2025 840I, 2020-2022 740LI, 2019-2020 X7, and X5 vehicles. After repeated attempts, the starter motor may overheat from an electrical overload.
Is it safe to drive a 2021-2025 840I with recall 25V644?
NHTSA has not told owners to stop driving, but the risk is real: An overheated starter motor can ignite nearby combustible material in the engine compartment, increasing the risk of a fire.
NHTSA describes the risk this way: An overheated starter motor can ignite nearby combustible material in the engine compartment, increasing the risk of a fire.
NHTSA has not issued a do-not-drive or park-outside warning for this recall. Still, get the repair done as soon as it is available, and stop driving if you notice symptoms related to the starter assembly.
Which vehicles are included in recall 25V644?
Recall 25V644 covers 145,102 vehicles: 2021-2022 BMW 740LI; 2021-2025 BMW 840I.
NHTSA lists 145,102 vehicles in this campaign. Not every vehicle of these models and years is included, so check your VIN.
| Model years | Make | Model |
|---|---|---|
| 2021-2022 | BMW | 740LI |
| 2021-2025 | BMW | 840I |
What is the fix for the 840I starter assembly recall?
Yes. Dealers will replace the engine starter, free of charge.
Dealers will replace the engine starter, free of charge. This recall includes vehicles repaired under recall 24V576 and those owners will need to have their vehicle repaired again. Owner notification letters were mailed February 9, 2026. Owners may contact BMW customer service at 1-800-525-7417. Vehicle Identification Numbers (VINs) involved in this recall became searchable on NHTSA.gov November 17, 2025.
When was recall 25V644 announced?
BMW of North America, LLC reported recall 25V644 to NHTSA on September 25, 2025. NHTSA lists the owner letter date as February 9, 2026.
| Date | What happened |
|---|---|
| September 25, 2025 | BMW of North America, LLC filed the defect report with NHTSA; NHTSA assigned campaign 25V644000. |
| February 9, 2026 | Owner notification letters mailed (per NHTSA). |
This recall was filed 12 months ago. If your 840I was built in that window, the VIN check below is the way to confirm it is included.
How do I check if my 840I is part of recall 25V644?
Enter your 17-character VIN at nhtsa.gov/recalls. If recall 25V644 is open on your 840I, it will be listed there.
Enter your 17-character VIN at NHTSA’s recall lookup. It shows any open safety recall on your vehicle, including 25V644000. Your VIN is on the registration card, the insurance card, and the driver side of the dashboard where it meets the windshield. Recent recalls can take a few days to appear in the lookup.
What should 840I owners do about recall 25V644?
Check your VIN, schedule the free recall repair, and keep a repair order for every dealer visit.
- Check your VIN at nhtsa.gov/recalls to confirm recall 25V644000 applies to your 840I.
- Book the recall appointment with any authorized BMW dealer. Ask up front whether parts are available and how long the vehicle will be there.
- Get a repair order for every visit, even if the dealer only inspects the vehicle. Read it before you leave and make sure your complaint is written the way you described it.
- Write down when symptoms involving the starter assembly happen: date, mileage, speed, weather and what you felt or heard. Photos and short videos help.
- Count the days the vehicle is at the dealer. Days out of service add up toward California's 30-day presumption.
- If the problem comes back after the repair, return to the dealer and contact a lemon law attorney.
What are 840I owners reporting to NHTSA?
Owners have filed 13 complaints with NHTSA about these vehicles since 2020, 9 of them about the electrical system.
Since recall 25V644 was reported on September 25, 2025, owners have filed 8 complaints with NHTSA about the electrical system on these vehicles. 0 of them (0%) describe the same problem happening more than once or coming back after a repair attempt.
How we counted: we matched NHTSA owner complaints for the model years in this recall that list the electrical system and were received on or after September 25, 2025, then flagged narratives that describe a repeat failure or a problem returning after a dealer repair, recall service or software update. Data from NHTSA, accessed October 1, 2026. Complaints are unverified owner reports and may involve a related electrical system issue rather than this exact defect; automated text matching can miss or misread some reports.
NHTSA’s public complaint database lists 13 owner complaints filed since 2020 for the vehicles in this recall, and 9 of them involve the electrical system. Complaints are reports from owners and have not been verified by NHTSA, but a high count for the same component is a sign the problem is widespread.
- 2022 BMW 840I: 7 complaints in total, 6 about the electrical system
- 2022 BMW 740LI: 4 complaints in total, 3 about the electrical system
- 2024 BMW 840I: 2 complaints in total, 0 about the electrical system
- 2021 BMW 740LI: 0 complaints in total, 0 about the electrical system
- 2021 BMW 840I: 0 complaints in total, 0 about the electrical system
- 2023 BMW 840I: 0 complaints in total, 0 about the electrical system
- 2025 BMW 840I: 0 complaints in total, 0 about the electrical system
Examples of what owners have reported to NHTSA (unverified excerpts):
The contact owns a 2022 BMW 840I. The contact stated that while driving at 5 MPH, the vehicle stalled unexpectedly. There were no warning lights illuminated. The vehicle was blocking the garage. The contact received notification of NHTSA Campaign Number: 25V644000 (Electrical System).
2022 BMW 840I owner, CO, NHTSA complaint 11700556, filed November 20, 2025
Customer filing a complaint against BMW for untimely resolution of Recall #25V644. This recall is a known Safety Risk which began in the summer of 2025. It is now December 4, 2025, and discussions today with BMW North America, they cannot provide me an ETA of when parts will be available for my vehicle.
2022 BMW 840I owner, TX, NHTSA complaint 11702940, filed December 4, 2025
In September 2025, BMW issued a recall # 25V644 for a safety related potential fire issue on the starter for my 2022 840i Gran Coupe. It has now been 4 months, and BMW is still telling me they do not have the assigned parts to resolve this issue.
2022 BMW 840I owner, TX, NHTSA complaint 11713303, filed January 26, 2026
Can recall 25V644 make my 840I a lemon in California?
Not by itself. A recall repair that fails, or repeat dealer visits for the same defect, can support a California lemon law claim.
A recall by itself does not make a car a lemon. Under California's Song-Beverly Consumer Warranty Act, what matters is whether a defect covered by the warranty substantially impairs the vehicle's use, value or safety, and whether the manufacturer or its dealers fixed it within a reasonable number of attempts (Civ. Code 1793.2(d)).
Intermittent electrical problems are a frequent source of repeat repair visits: the dealer cannot reproduce the fault, the owner brings the 2021-2025 BMW 840I back, and the problem shows up again.
This campaign follows an earlier recall for the same issue. A second recall can mean the first remedy failed, and repeated repair attempts on the same defect are the core of most lemon law claims.
Earlier campaigns on these vehicles involving the same component: 24V576000.
Civil Code 1793.22(b) sets out a presumption that applies in the first 18 months or 18,000 miles: two or more repair attempts for a defect likely to cause death or serious bodily injury, four or more attempts for the same defect, or more than 30 total days out of service for repairs. Written notice to the manufacturer is required in some cases. Owners outside that window can still have a claim.
An owner who prevails in a lemon law case can recover reasonable attorney fees and costs from the manufacturer (Civ. Code 1794(d)). You pay nothing, win or lose. We are paid only if you win, and the manufacturer pays our fees, including in settlements. If a case is lost, our firm covers the costs.
In our cases, a recall repair visit counts as a repair attempt, and it's strongest when the owner complained about the problem before the recall came out. A recall shows the defect is real and that enough owners reported it for the manufacturer to issue a fix.
The biggest mistake I see is waiting too long. The mileage offset starts at your first repair visit for the problem, so the sooner you take it in, the better. If the problem comes and goes, take it in when it happens. You can't go back to that date later.
If you get a recall notice, call a lemon law attorney right away. You may have taken the car in for the same problem before and forgotten, or there may be other recalls related to it.
Jacob Shayesteh, Esq. (SBN 362320), Founder and Managing Attorney. Quotes lightly edited for clarity. Prior results do not guarantee a similar outcome.
Has your 840I been back to the dealer for this problem?
Call 877-536-6620Other BMW 840I recalls
Frequently asked questions about recall 25V644
Did the recall 25V644 fix work?
Since recall 25V644 was reported on September 25, 2025, owners have filed 8 complaints with NHTSA about the electrical system on these vehicles. 0 of them (0%) describe the same problem happening more than once or coming back after a repair attempt. If your vehicle still has the problem after the recall repair, go back to the dealer, get a repair order, and talk to a lemon law attorney.
When will owners be notified?
According to NHTSA, owner notification letters were or are scheduled to be mailed February 9, 2026.
Is the 25V644000 recall repair free?
Yes. Safety recall repairs are done free of charge at authorized dealers.
How do I know if my 840I is part of recall 25V644000?
Enter your 17-character VIN in NHTSA's recall lookup at nhtsa.gov/recalls, or call a dealer. The VIN is on your registration, insurance card and the lower corner of the windshield.
Does a recall mean my car is a lemon?
Not on its own. A lemon law claim depends on whether a covered defect keeps coming back or keeps the vehicle out of service. A recall repair that fails, or repeat visits for the same problem, can support a claim.
Does the recall fixing my car mean I have no case?
Not necessarily. Even if the recall repair fixed it, you may still have a case, and a car that's a year or more old can still qualify.
Do used cars qualify for California lemon law?
We take certified pre-owned, demo and dealer vehicles. Since the California Supreme Court's Rodriguez decision in 2024, ordinary used cars generally do not qualify.
How long does a recall lemon law case take?
Recall-related cases typically resolve in one to three months from your first call. Prior results do not guarantee a similar outcome.
What does a lemon law attorney cost?
You pay nothing, win or lose. We are paid only if you win, and the manufacturer pays our fees, including in settlements. If a case is lost, our firm covers the costs.
Sources
- NHTSA recall record 25V644000 (recall report and owner letters are posted there)
- NHTSA complaints and recalls data, accessed October 1, 2026
- California Civil Code 1793.2 and 1793.22
Attorney advertising. America’s Lemon Lawyer is a trade name of Wynn Law Group, APC. Responsible attorney: Jacob Shayesteh, Esq. (SBN 362320). This page is general information, not legal advice. America’s Lemon Lawyer is not affiliated with NHTSA or BMW. Prior results do not guarantee a similar outcome.