2004 MINI Cooper S

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).

WAS DRIVING CAR ON 18 JULY 2020 AND POWER STEERING QUIT WORKING AND MADE STEERING DIFFICULT, ALSO COOLANT FAN,LOW SPEED AND HIGH SPEED STOPPED WORKING SAME TIME AS POWER STEERING QUIT. THE ASC LIGHT CAME ON AND IT WILL NOT TURN OFF. NO BLOWN FUSES IN ENGINE COMPARTMENT OR BY DRIVERS KICK PANEL. I WAS DRIVING THE CAR ON A STATE ROAD WHEN THIS OCCURRED.

NHTSA ID

11340300

Incident

Jul 18, 2020

Mileage

116,543 mi

TL* THE CONTACT OWNS A 2004 MINI COOPER S. THE CONTACT STATED THAT WHILE DRIVING AT ATTEMPTING TO MAKE A TURN, THERE WAS AN ABNORMAL GRINDING SOUND COMING FROM THE STEERING COLUMN. THE CONTACT ALSO STATED THAT THERE WAS A POWER STEERING FLUID LEAK PRESENT. THE FAILURE WAS INTERMITTENT. THE VEHICLE WAS TAKEN TO MINI OF STEVENS CREEK LOCATED AT (4201 STEVENS CREEK BLVD, SANTA CLARA, CA 95051), AND DIAGNOSED. THE CONTACT WAS INFORMED THAT THE STEERING PUMP NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 156,000.

NHTSA ID

11319854

Incident

Feb 29, 2020

Mileage

156,000 mi

THE POWER STEERING IS VERY STIFF TO DRIVE AND CANNOT DRIVE MY COOPER BECAUSE I CAN NO LONGER STEER THE VEHICLE.

NHTSA ID

11302434

Incident

Dec 13, 2019

WHEN YOU TURN WHEEL LEFT OR RIGHT IT MAKES A NOISE AND IT'S VERY HARD TO TURN. SO I THINK IT'S THE STEERING: ELECTRIC POWER ASSIST SYSTEM. RECALL ID # 240625.

NHTSA ID

11282548

Incident

Nov 24, 2019

ALL MODELS FROM 2005 ONWARD HAVE BEEN RECALLED, YET EARLIER MODELS HAVE THE SAME PROBLEMS WITH NON FUNCTIONING AIRBAGS. THE AIRBAG WARNING LIGHT IS ON CONTINUALLY, AND THERE ARE KNOWN PROBLEMS WITH WIRING, PRESSURE MATS AND CONNECTORS IN THESE VEHICLES. BMW IS INTENTIONALLY IGNORING THESE ISSUE. MY OWN PERSONAL VEHICLE HAS THIS PROBLEM AND AS A GOVERNMENT MANDATED SAFETY DEVICE I BELIEVE THAT EARLIER MODELS OF MINI COOPERS SHOULD BE INCLUDED IN THE RECALL!

NHTSA ID

11228472

Incident

Jun 30, 2019

AIRBAG LIGHT COMES ON AND STAYS ILLUMINATED. WE ARE UNSURE IF THE SYSTEM IS WORKING PROPERLY. WE HAVE NOT RUN DIAGNOSTIC CODES ON THE SYSTEM.

NHTSA ID

11101430

Incident

Jun 11, 2018

Mileage

121,348 mi

THE VEHICLE WAS HARD TO STEER AND SMOKE WAS COMING FROM THE ENGINE. TOOK THE CAR HOME, DID NOT SEE FLAMES, PARKED CAR IN THE DRIVEWAY SWITCHED CARS AND LEFT. RECEIVED A CALL FROM THE FIRE DEPARTMENT THAT MY MINI WAS ON FIRE AND I NEEDED TO RETURN TO MY HOUSE.

NHTSA ID

11015001

Incident

Aug 6, 2017

Mileage

165,000 mi

THE POWER STEERING IN MY 2004 MINI COOPER S FAILED LAST MONTH, PROMPTING ME TO RESEARCH WAYS TO FIX THE VEHICLE ONLINE. I FOUND THAT MINI USA HAD ISSUED A RECALL ON MY CAR, BUT WAS INFORMED BY THE DEALERSHIP AND THEN MINI THAT MY VIN NUMBER DID NOT FALL AMONG THOSE VEHICLES RECALLED. I'M WONDERING WHETHER MINI APPROPRIATELY LIMITED THEIR RECALL CONSIDERING MY VEHICLE HAS THE SAME PROBLEM THAT PROMPTED THE RECALL, AND FALLS WITHIN THE SAME MODEL AND YEAR RANGE. I THINK THE DEPARTMENT SHOULD INVESTIGATE WHETHER TO EXPANDING THE RECALL.

NHTSA ID

11012888

Incident

Jul 6, 2017

Mileage

84,000 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.

Programming a Replacement EGS Module with ISTA/P. Programming a replacement electronic transmission control module (EGS) with ISTA/P requires the manual entry of the correct target basic and programmed part numbers. Programming concept.

NAVIGATION SYSTEM HAS MISSING OR INCORRECT ROAD MAP DATA: The route guidance is inaccurate and therefore irritating to the customer; or it is not possible to locate certain addresses, for instance:

NAVIGATION SYSTEM HAS MISSING OR INCORRECT ROAD MAP DATA: The route guidance is inaccurate and therefore irritating to the customer; or it is not possible to locate certain addresses, for instance:

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: BECAUSE OF THE DME SOFTWARE, AND A DAMAGED CLUTCH, THE DRIVETRAIN MALFUNCTION CHECK MESSAGE APPEAR. *MA