They Break Too?! Engines and Transmissions from Famous Brands That Kept Failing

Recalling the Most Problematic Designs from BMW, Hyundai, Ford, and Other Major Auto Brands (Excluding China).

Chinese cars are often called disposable, with claims that their key components and assemblies have a short lifespan and poor repairability. However, even well-known brands are not immune to technical missteps. Here are five notable cases where popular automakers faced criticism for design flaws and failures.

BMW N63

BMW’s N63 V8 gasoline engines debuted in 2008, featuring an unconventional design with exhaust manifolds and turbochargers placed between the cylinder banks. However, this configuration turned out to be a major misstep—the turbos and catalytic converters generated extreme heat, effectively “roasting” nearby components like fuel injectors, sensors, and wiring. Overheating also caused premature valve stem seal wear, piston ring coking, excessive oil consumption, and failures in injectors and the timing chain. A flood of complaints forced BMW to redesign the engine and compensate owners.

In the U.S., BMW even faced class-action lawsuits. A settlement was eventually reached, offering customers reimbursements for oil expenses and towing costs, free battery replacements, and discounts on servicing. Some unlucky owners had their engines replaced entirely at BMW’s expense, though this was not universal. The company covered full engine replacements only in the U.S. for warranty vehicles with less than 80,000 km (50,000 miles) if a major rebuild didn’t solve the problem.

BMW continued refining the N63 engine until 2018, undergoing nearly a decade of revisions that saw almost every component reworked. As a result, used 5 Series, 6 Series, 7 Series, X5, and X6 models with the 50i badge (2008–2019) should be approached with caution. Even later versions of the 4.4-liter V8 remain high-maintenance and service-sensitive.