2005 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).

The contact owns a 2005 Mini Cooper S. The contact stated while driving 25 MPH, the steering wheel became difficult to maneuver. The contact stated that the vehicle had lost power steering assist. The vehicle was not diagnosed or repaired. The contact stated that a software update was performed on the back over prevention camera. The manufacturer was notified of the failure but offered no assistance. The contact related the failure to NHTSA Campaign Number: 15V660000 (STEERING); however, the VIN was not included in the recall. The contact was referred to the NHTSA Hotline for assistance. The failure mileage was 175,830.

NHTSA ID

11655045

Incident

Feb 15, 2025

Mileage

175,830 mi

The contact owns a 2005 Mini Cooper S. The contact received notification of NHTSA Campaign Number: 15V660000 (Steering) however, the part to do the recall repair was not yet available. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The contact also stated that he was advised by the dealer that he had to pay out of pocket for a diagnostic test. The manufacturer was made aware of the issue. The contact had not experienced a failure. Parts distribution disconnect.

NHTSA ID

11458164

Incident

Mar 22, 2022

BATTERY LIGHT FLASHING, POWER STEERING CUTTING OUT INTERMITTENTLY WHILE DRIVING. ALTERNATOR AND SERPINTINE BELT REPLACED BUT PROBLEM CONTINUES. ELECTRIC POWER STEERING SEEMS TO BE DRAINING ELECTRICAL SYSTEM.

NHTSA ID

11362085

Incident

Sep 26, 2020

Mileage

172,450 mi

TL* THE CONTACT OWNS A 2005 MINI COOPER S. THE CONTACT STATED THAT WHILE DRIVING AT 30 MPH, THE VEHICLE OVERHEATED AND SMOKE BEGAN COMING FROM UNDER THE HOOD OF THE VEHICLE. THE CONTACT TOOK THE VEHICLE TO AN INDEPENDENT MECHANIC WHERE THE WATER PUMP WAS REPLACED. AFTER THE REPAIR, THE POWER STEERING CEASED WITHOUT WARNING UPON STARTING THE VEHICLE. THE CONTACT REFERENCED NHTSA CAMPAIGN NUMBER: 15V660000 (STEERING) AS POSSIBLE CAUSE OF THE FAILURE HOWEVER, THE VIN WAS NOT INCLUDED. MINI OF DES MOINES LOCATED AT (9900 HICKMAN RD, DES MOINES, IA 50325) WAS CONTACTED AND CONFIRMED THAT THE VIN WAS NOT INCLUDED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 75,000.

NHTSA ID

11317775

Incident

Aug 13, 2019

Mileage

75,000 mi

TL* THE CONTACT OWNS A 2005 MINI COOPER S. WHILE DRIVING VARIOUS SPEEDS, THE CONTACT EXPERIENCED INTERMITTENT POWER STEERING FAILURE. THE CONTACT ASSOCIATED THE FAILURE WITH NHTSA CAMPAIGN NUMBER: 15V660000 (STEERING); HOWEVER, MINI OF MARIN (5880 PARADISE DR, CORTE MADERA, CA 94925, (415) 887-2194) AND THE MANUFACTURER WERE CONTACTED AND STATED THAT THE VEHICLE WAS NOT INCLUDED IN A RECALL. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE FAILURE MILEAGE WAS UNKNOWN.

NHTSA ID

11243771

Incident

Jun 10, 2019

POWER STEERING NO LONGER WORKS.

NHTSA ID

11242896

Incident

Feb 22, 2019

Mileage

150,000 mi

THE CAR WAS IN MOTION WHEN SUDDENLY THE STEERING WHEEL BECAME VERY HARD AND THE DRIVER LOST CONTROL, ALMOST CAUSING AN ACCIDENT. THERE HAS BEEN A RECALL FOR MINI COOPER S VEHICLES (15V-XXX SAFETY RECALL) INVOLVING THE ELECTRIC-HYDRAULIC POWER STEERING SYSTEM. THE RECALL INCLUDES 2002-2005 MODELS, AND EXTENDS THE WARRANTY UP TO 13 YEARS OR UP TO 150,000 MILES. OUR VEHICLE FALLS UNDER THOSE REQUIREMENTS, AND IS A 2005 MODEL AND HAS 69,751 MILES, YET WE WERE TOLD THAT THERE ARE NO EXISTING RECALLS FOR OUR VEHICLE, EVEN THOUGH WE SUSPECT THAT THE INCIDENT WE HAD INVOLVES THE HYDRAULIC STEERING SYSTEM.

NHTSA ID

11230307

Incident

Jul 4, 2019

Mileage

69,751 mi

WHEN ADJUSTING THE DRIVER AND PASSENGER SEATS, THE AIRBAG LIGHT ILLUMINATED. AFTER RESEARCHING ONLINE, I CONDUCTED TROUBLESHOOTING. I VERIFIED THAT THE WIRING HARNESSES AND CONNECTORS FOR THE AIRBAG SENSORS UNDER BOTH SEATS HAD COME LOOSE, AND CERTAIN WIRES DE-PINNED. THE CAR WAS RUNNING, AND PARKED WHEN THIS OCCURRED.

NHTSA ID

11186059

Incident

Mar 9, 2019

Mileage

62,527 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:

AISIN AUTOMATIC TRANSMISISON: RIGHT SIDE OUTPUT SHAFT SEAL REPLACEMENT

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.