E53 X5 Front Air Suspension Bag Blowing Up?

[richardb]

So I recently picked up a beautiful 2004 X5 4.4i in Imola II with every option you can imagine. It has the EHCII 4-wheel air suspension, and is beginning to be a problem.

One year ago, or 5000 miles ago, the previous owner had the air supply control module replaced at her local BMW dealer for around $1300!

After driving my first 900 miles, the driver front air bag leaked enough to set off the self-level-suspension inactive warning and lower the front of the car, making it no longer drivable.

I ordered an Arnott remanufactured strut for the driver front (left) and replaced it. My local shop cleared the SLS error (oddly, there was no fault code present) and the car drove like new for about 5 miles. While idling in my driveway, I heard a huge pop as loud as fireworks! The new airbag blew by the upper crimp ring and deflated. The front of the car leveled back all the way down.

After contacting Arnott, they sent out a replacement immediately with free 2-day shipping. We thought that surely it was a (very rare) manufacturing defect.

I replaced the strut a second time, it drove like a new X5 for 5-6 miles, and while coming to a stop sign, I hear a "Pshhhhhhh" and the front left strut blew out around the seal AGAIN.

Other notes:
* The front level height sensors are in-tact and appear to be working
* No codes present
* The compressor works and all 3 ride levels worked via the control button
* The other three corners are original, are swollen, but hold air at this point

So, do you guys think this is a manufacturing defect of the crimp ring, or is this left front strut being over-inflated to the point of bursting? What component would cause only one strut to over-inflate -- if that is the issue?

At this point, I am not sure what direction to go. I'm waiting to hear from Arnott's engineering team.

Here's a shot of the reman strut that blew:

https://youtu.be/gbd_EUJojyQ