BMW 540i Ballast Resistor Replacement at your home or office.

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Ballast Resistor Replacement Service

How much does a Ballast Resistor Replacement cost?

On average, the cost for a BMW 540i Ballast Resistor Replacement is $430 with $335 for parts and $95 for labor. Prices may vary depending on your location.

CarServiceEstimateShop/Dealer Price
1994 BMW 540iV8-4.0LService typeBallast Resistor ReplacementEstimate$784.53Shop/Dealer Price$969.42 - $1484.70
1995 BMW 540iV8-4.0LService typeBallast Resistor ReplacementEstimate$764.53Shop/Dealer Price$949.45 - $1464.75
Show example BMW 540i Ballast Resistor Replacement prices

What is the Ballast Resistor all about?

Modern ignition systems use electronic circuitry to control voltage during engine starting and operation, but it wasn’t always this way. Older vehicles with points and coils did not have the benefit of circuit boards and computers, so another way to control voltage was needed. The ballast resistor coil was the solution. Think of it as a giant fuse in a way, although it serves a much greater purpose.

The ballast resistor coil plays several roles in your engine and charging system. In terms of position, it’s located between the ignition switch and the positive battery cable. During engine operation, the ballast resistor is responsible for lowering voltage applied to the coil to ensure that it doesn’t overheat and burn out, or damage the battery. During cranking, the ballast resistor allows normal battery voltage into the coil to ensure a good, strong spark for starting the engine.

The ballast resistor is subjected to significant amounts of heat during operation (the resistor’s resistance level increases or decreases with the application of heat and voltage). Over time, it will eventually wear out and need to be replaced.

Keep in mind:

  • The ballast resistor is not inspected during normal maintenance.
  • The ballast resistor is subject to significant amounts of wear and tear.
  • Ballast resistors are not generally found on fuel-injected engines.

How it's done:

  • The Ballast Resistor is verified that it needs to be replaced. The battery and battery tray are removed.
  • The defective Ballast Resistor disconnected and removed.
  • The new Ballast Resistor is installed, secured, and connected.
  • The battery tray and battery are reinstalled. The Ballast Resistor is tested for operation.
  • The vehicle is tested to ensure proper operation of the Ballast Resistor and road tested to ensure fan operation.

Our recommendation:

Over time and through normal use, the ballast resistor is subject to a great deal of wear and tear, and heat. This can cause it to fail unexpectedly. When this happens, your vehicle will experience unwanted, and perhaps dangerous, operation. It may crank but then stop running immediately after. Have any starting problems immediately diagnosed by one of our expert mechanics.

What common symptoms indicate you may need to replace the Ballast Resistor?

  • Engine cranks, but dies immediately when the key is moved back to the run position from the start position

How important is this service?

Without a ballast resistor, your engine will not operate unless you jump the resistor, which is dangerous, as it will eventually burn out the points, and is not recommended. If your engine dies immediately after turning the key back to run from start, likely the ballast resistor needs to be replaced. If the engine runs with the key in the run position, you may have another issue. Have it properly diagnosed by one of our expert mechanics immediately.

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Excellent Rating

(60)

Rating Summary
56
3
0
0
1
56
3
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1

Amor

43 years of experience
181 reviews
Amor
43 years of experience
BMW 540i V8-4.4L - i need a quote how much does it cost to replace cam shaft sensor for 1998 bmw 540i - Newark, California
no other comment but to say Amor successfully solved the problem of my car again which is replacing the cam shaft censor in which other mechanic was unsuccessfully solve the same problem.

Robert

21 years of experience
64 reviews
Robert
21 years of experience
BMW 540i V8-4.4L - Car is not starting - Lynnwood, Washington
Robert was incredibly thorough and did an excellent job. He was very friendly and professional. I will be using his services again in the future.

Tom

42 years of experience
205 reviews
Tom
42 years of experience
BMW 540i V8-4.4L - Window Motor / Regulator Assembly Replacement (Driver Side Front) - Campbell, California
Yourmechanic.com is awesome! It was so simple to get on their website, tell me exactly what I needed done and get an instant quote. I got an excellent price, the mechanic Tom came to my home on time, was very friendly and fixed the window on my BMW. Tom is the best! I will ABSOLUTELY use them again and refer them to everybody I know. I am a very satisfied customer!

Kyle

22 years of experience
55 reviews
Kyle
22 years of experience
BMW 540i V8-4.4L - Engine is sputtering - Suwanee, Georgia
A pleasure to work with...

Excellent Rating

(60)

Rating Summary
56
3
0
0
1
56
3
0
0
1
Number of BMW 540i services completed
660+
services done by our mechanics
TOTAL NUMBER OF EXPERT BMW MECHANICS
1100+
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