S62 engine replacement/ failed connector rod bushing.
Soooooo. It finally happened; you always hear about that guy who had his engine eat itself. Well here I am! Connecting rod bushing disintegrated into two large parts and many shavings and circulated through the oil system. (@49650 miles and Dinan S package by Chris Welch) Car is now at Irvine BMW awaiting an after-market rep to 'o.k.' or 'decline' the recommendation to replace the motor after conducting a 'investigation'. (Millenium warranty- Platinum Plan) Total estimated cost of repair= $35K. Needless to say, Millenium is attempting to find any reason to not perform this claim. Does anyone else have any experience with Millenium or any other warranty company and/or info on failed connecting rods, such as, how many E39/S62 engines have experienced this? Maybe after I drink myself to sleep, I'll wake up and find one of you has everything figured out on this... or has a f'ing magic wand!
No experience with the warranty company and hope that it works out for you. Curious how the car was driven over its 50K life. I suspect there are a lot of members with well over 50K miles without a warranty and are thinking, how did this happen? Any input you can offer would be cool. If you are not comfortable due to the open warranty claim, I understand. Either way, good luck!!
Rob bearing failures are the most common catastrophic issue with the engine. As has been written about fairly extensively here, one culprit is excessive rpm from an elevated engne speed limiter with a chipped engine, but other members have experienced spun bearings for no apparent reason. Of course one can always destroy an engine from an unintended downshift during 10/10's operation.
What the investigation will entail is interrogating the ECU for engine speed data. They will probably try to nail you on this if they don't nail you for the chip.
Sorry to hear about your motor being toast, I have less than 100% faith in warranties but good luck with yours. If you get a new motor out of the deal, don't mess around with mods, just go straight forced induction!