2005 MINI Cooper Convertible

The Office of Defects Investigation (ODI) originally opened the investigation of loss of power steering assist in model year (MY) 2004 and 2005 Mini Cooper as Preliminary Evaluation PE10-038.The investigation was upgraded to Engineering Analysis EA11-005 in May, 2011.During EA11-005 the scope was expanded to include MY 2002 and 2003 vehicles that use the same steering system.The subject vehicles now include MY 2002, the first year BMW sold MINI in the U.S., through mid-MY 2005 covering approximately 109,000 vehicles.The subject vehicles use an electrically driven pump to provide hydraulic pressure to a conventional rack-and-pinion steering gear.A pump, the electric motor, and an electronic control unit (ECU) are housed in a single component BMW calls a Power Pack.The investigation focused on contaminant-induced failure of the ECU resulting in a loss of assist without warning.When assist is lost mechanical steering is retained however increased steering effort is required to keep the vehicle on an intended path.Some consumers reported that restarting the vehicle (cycling the ignition switch) would often reinstate the steering assist.Additionally, and by design, assist can also reinstate during the drive cycle in limited circumstances.The unexpected loss of assist, and/or possibly the reinstatement of assist while driving, may contribute to a loss of vehicle control in certain driving situations.During MY 2005 production BMW introduced a revised Power Pack design (the ECU incorporated a conformal coating of the circuit board) which resulted in a significant reduction in failures.ODI identified 20 reports describing crashes consistent with a loss of power assist event possibly caused by a failure of the Power Pack.Two reports alleged an injury however both were minor in nature and did not require emergency treatment (a subsequent doctor's visit occurred in one case).Ten of these reports described low speed crashes with minimal, or in most cases no property or vehicle damage (e.g., striking a movable barrier in a parking lot).Additionally 27 other reports alleged or indicated that a crash occurred due to a Power Pack failure however in reviewing these reports, ODI either 1) was unable to confirm that a crash actually occurred (8 reports), or 2) determined that the crash circumstances (e.g., adverse road/weather conditions) or cause (e.g., the crash was caused by steering linkage failure) were not attributable to a Power Pack failure (19 reports).Throughout the investigation BMW maintained that loss of assist in the subject vehicles did not constitute a safety related defect, noting that the subject vehicles are smaller, light weight vehicles that can be reasonably controlled when assist is lost.In May 2013 BMW launched a 13 year/150,000 mile extended warranty coverage utilizing the redesigned Power Pack as a replacement part.ODI continued its investigation.In July 2014 BMW provided ODI a status of the ongoing extended warranty program, and in May 2015 ODI requested an update of complaint data.Following a review of the provided data, ODI informed BMW of its assessment that loss of steering assist failures were not adequately resolved by an extended warranty program.On October 12, 2015 BMW notified NHTSA that it would conduct a safety recall (15V-660) on approximately 86,000 subject vehicles not previously remedied with the new design Power Pack through regular or extended warranty programs.The recall covers MY 2002-2005 MINI Cooper, MY 2002-2005 MINI Cooper S, and MY 2005 MINI Cooper/Cooper S convertibles manufactured through Feb 9, 2005.Vehicles produced after this date are not included si

ODI has received 339 complaints alleging an unexpected loss of power steering assist while driving the vehicle.When the power steering assist stops working, drivers experienced difficulty in steering and/or controlling the vehicle.According to BMW drivers may experience either a temporary or permanent loss of power steering assist.BMW further advised that a temporary loss of power steering assist may be due to a malfunctioning cooling fan or an under-voltage condition in the power steering system.A permanent loss of power steering assist may be due to an error in the internal electronics, and may also result in the continuous running of the power steering pump.The VOQ complaints allege 5 minor crashes and 3 fires.The crashes are described as hit the curb.The fires are described as melted wires. There were no property damage claims.ODI has received similar complaints for other model year Mini.Additional information is required to evaluate the frequency, consequence, and scope of this issue.Accordingly the investigation has been upgraded to an Engineering Analysis (see EA11-005).

The contact owns a 2005 Mini Cooper Convertible. The contact stated that she noticed a leak coming from the vehicle. The contact took the vehicle to an independent mechanic, where it was diagnosed with a power of steering hose leak. The vehicle was not repaired. The contact related the failure to NHTSA Campaign Number: 15V660000 (Steering). The manufacturer was made aware of the failure. The failure mileage was approximately 94,000.

NHTSA ID

11510859

Incident

Mar 7, 2023

Mileage

94,000 mi

The transmission will cycle first through third and when it tries to go into 4th it slips and will not operate higher gears it caused me to lose my forward drive momentum as I was switching lanes and the car I was getting in front of almost ran into me.

NHTSA ID

11452775

Incident

Sep 5, 2021

My son drives this car and the power steering went out twice on him while driving. I need to get the pump replaced via the recall, but the nearest location is 200 miles from me. It is not safe to drive this car that far and I would have to drop it off and make another trip to pick it up. Towing that far would cost a small fortune. I called every number and was transferred to several people to help with this issue. They say they can not and won't help me till I get the car to a dealership to fix it. One person from Mini told me I might be able to go to a certified mechanic but when I asked the next person they said it had to be a dealership. I spent two days on the phone with several people from Mini and no one was willing to offer a solution. I drive this car to get the recall fixed and something happens and the car wrecks, or worse someone is killed, who would it be on then? No happy about this at all.

NHTSA ID

11444553

Incident

Nov 29, 2021

The contact owns a 2005 Mini Cooper Convertible. The contact received notification of NHTSA Campaign Number: 15V660000 (Steering). The contact stated that while her son was driving at an undisclosed speed, the power steering assist failed. The dealer was made aware of the recall but informed the contact that they do not service recall repairs. The nearest dealer that was able to service the recall repair was located 177 miles away. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure mileage was unavailable.

NHTSA ID

11444173

Incident

Dec 17, 2021

POWER STEERING PUMP STOP WORKING WHILE DRIVING TURNING IN A CITY STREET

NHTSA ID

11414376

Incident

Apr 28, 2021

Mileage

100,000 mi

TL* THE CONTACT OWNED A 2005 MINI COOPER CONVERTIBLE. THE CONTACT STATED THAT WHILE DRIVING AT 5 MPH AFTER EXITING HIS DRIVEWAY, HE SUDDENLY LOST POWER STEERING WITHOUT WARNING. AS A RESULT OF THE FAILURE, THE CONTACT LOST COMPLETE CONTROL OF THE VEHICLE AS THE VEHICLE VEERED OFF THE ROAD AND INTO A UTILITY POLE. THE CONTACT WAS UNAWARE IF THE AIR BAGS DEPLOYED UPON IMPACT. THE CONTACT STATED THAT HE EXITED THE VEHICLE, WALKED BACK TO HIS HOME AND TOOK A NAP. AN HOUR LATER, THE CONTACT STATED THAT HE WAS AWOKEN BY A SHERIFF'S DEPUTY WHO ASKED HIM QUESTIONS ABOUT THE INCIDENT WITH HIS VEHICLE. A POLICE REPORT FILED AND THE CONTACT LATER WENT TO A DOCTOR WHERE HE WAS TREATED FOR INJURIES FOR HIS LOWER BACK WHICH INCLUDING A SLIPPED DISC AND A BRUISED VERTEBRAE. DUE TO THE FAILURE, THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC WHERE THE VEHICLE WAS DESTROYED. RECENTLY, THE CONTACT RECEIVED A RECALL NOTICE FOR NHTSA CAMPAIGN NUMBER: 15V660000 ( STEERING) WHICH HE LINKED TO HIS VEHICLE FAILURE. THE CONTACT REACHED OUT THE MANUFACTURER WHERE HE WAS ASKED QUESTIONS ABOUT HIS VEHICLE FAILURE; HOWEVER, THE CONTACT REFUSED TO ANSWER ANY QUESTIONS AND DECIDED TO SEEK LEGAL ADVICE. THE VEHICLE WAS DEEMED DESTROYED. THE FAILURE MILEAGE WAS UNKNOWN.

NHTSA ID

11404624

Incident

May 2, 2017

THE CAR STOPPED STEERING CORRECTLY. IT IS VERY DIFFICULT TO TURN THE WHEELS. THE POWER STEERING IS GONE. I STARTED NOTICING THE DIFFERENCE IN THE STEERING AND THEN THE STEERING PROGRESSIVELY GOT WORSE. I CALLED THE SERVICE DEPARTMENT OF THE DEALERSHIP TO ASK IF THERE SHOULD BE A CONCERN BECAUSE THE STEERING STARTED AFTER I HAD THE RECALL SERVICE ON THE SEAT WARMMER.

NHTSA ID

11057515

Incident

Dec 8, 2017

Mileage

10,200 mi

POWER STEERING PUMP GOES OUT FROM TIME TO TIME, BROUGHT IT TO MINI DEALERSHIPS ONCE AND WAS WORKING FINE WHEN WE BROUGHT IT IN, AND WAS TOLD NOTHING WAS WRONG, AND WAS SENT ON OUR WAY. NOW HAD TO DISCONNECT BATTERY TO REPLACE A PART, AND WHEN RECONNECTING THE BATTERY, POWER STEERING PUMPS RUNS AND WONT SHUT OFF. VEHICLE WAS STATIONARY. PLEASE HEP, AND THANK YOU.

NHTSA ID

10949672

Incident

Feb 3, 2015

Mileage

185,005 mi

MINI electrical systems have continued to develop over the past few years. As a result, the demand on the batteries has increased. Breakdowns due to an empty battery or problems in the vehicles electrical system can have various causes, most of which are not due to the battery itself. For this reason, a battery replacement will permanently eliminate the problem only in the rarest of cases. The energy diagnosis test module helps to localize these causes. This document covers important information for the dealer on how to handle “discharged battery” complaints. Without performing the energy diagnosis test plan, the root cause of a discharged battery cannot be identified. In order to properly repair the vehicle the first time, it is very important that the diagnostic test plan is performed to completion; with all results taken into consideration.

W10 ENGINE: EMS2K - COMPREHENSIVE COMPONENT OBD READINESS MONITOR NOT COMPLETED: An affected vehicle fails to pass a state Inspection and Emission (I/M) test due to the ÒComprehensive ComponentÓ OBD readiness monitor status is Ònot complete,Ó or it fails complete after performing an applicable repair.

This Service Information bulletin supersedes SI 32 02 14 dated August 2014. SUBJECT Installation of Right-Hand Drive Steering Spindle in Left-Hand Drive Vehicle is No Longer Required. Left-hand drive steering spindles are currently available.

MINI: FAULTY SOFTWARE FOR THE TANK VENTILATION CONTROL DISPLAYS ENGINE THROTTLE REACTION WHEN TEMPERATURE IS HIGH OUTSIDE, AND MORE OBVIOUS IF THE TANK IS ONLY PARTLY FILLED. *MA

MINI: SOME VEHICLES HAVE TURBOCHARGER NOISE AND A LACK OR LOSS OF PERFORMANCE, DUE TO RESTRICTION OF TURBOCHARGER OIL SUPPLY, RESULTING IN OIL STARVATION AND SEIZING OF TURBOCHARGER ASSEMBLY. MODEL ALL. *PE

Electro-Hydraulic Power-Assist Steering Pump (EHPS) and Cooling Fan: Limited Warranty Extension to 13 Years/150,000 Miles. On affected vehicles, the electro-hydraulic power steering (EHPS) pump can fail.