2004 MINI Cooper

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 2004 Mini Cooper. The contact received notification of NHTSA Campaign Number: 15V660000(STEERING); however, the part to do the recall repair was unavailable. The local dealer was contacted, and it was confirmed that the part was not available. The contact stated that the manufacturer exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The contact had experienced the failure, causing the driver to lose control of the steering and drive off the road. The exact cause of the failure was not determined, and the vehicle was not repaired. The manufacturer and local dealer were notified of the failure. The failure mileage was 160.000. Parts distribution disconnect.

NHTSA ID

11661001

Incident

Aug 30, 2024

Mileage

160,000 mi

Mini felt like it was getting pushed by the wind . Realized wasn't wind Mini loss of completely all functions of steering wheel. On super busy highway. Devine intervention Was in far left car went left to right lanes then hit median gaurd rail spun around Finally got it to stop. Never Hitting and hurting anyone around me. Nobody hit me. Car is totalled ! Still at tow place. I saw my life flash as cars were zooming by me. Someone should be held responsible for my car and almost my life. Called out of work can't move upper body that well.

NHTSA ID

11462281

Incident

Apr 24, 2022

MY WIFE WAS DRIVING OUR 2004 MINI COOPER HOME TRAVELING UPHILL ON A STEEP PAVED MOUNTAIN ROADWAY TRAVELING A MAXIMUM OF 15 MPH WHEN FOR SOME UNKNOWN REASON THE VEHICLE LEFT THE ROADWAY; STRUCK A TREE WITH ITS LEFT FRONT AND BURST INTO AN EXPLODING FIRE KILLING MY WIFE WHO WAS NOT ABLE TO ESCAPE THE BURNING VEHICLE. THE NC STATE POLICE ARE INVESTIGATING THE CAUSE OF THE FIRE AND DEATH. THEY DO NOT KNOW YET WHETHER THE VEHICLE CAUGHT FIRE PRIOR TO STRIKING THE TREE BUT, FEEL THE FIRE COULD NOT HAVE BEEN CAUSED BY THE VEHICLE STRIKING THE TREE AT A LOW IMPACT AND SPEED. NC MV ACCIDENT REPORT#[XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TT

NHTSA ID

11258958

Incident

Sep 6, 2019

Mileage

135,000 mi

MAINLY WHILE COLD AND AT LOW SPEED'S THE WHEEL SUDDENLY BECOMES VERY HARD TO TURN AND I WAS TOLD BY A MECHANIC BUT IT'S A FAULTY HYDRAULIC POWER STEERING PROBLEM

NHTSA ID

11209798

Incident

Apr 29, 2019

Mileage

201,000 mi

VERY HARD TO TURN STEERING WHEEL AT TIMES ESPECIALLY WHEN MOVING SLOWLY; COMING TO A TURN AT A LIGHT, BACKING OUT OF A PARKING SPOT, ETC.

NHTSA ID

11208085

Incident

Apr 28, 2019

Mileage

200,000 mi

2004 MINI COOPER PURCHASED NEW APROX 62 MILES ON IT AND THE CVT TRANSMISSION IS GONE & THERE WAS A CLASS ACTION LAWSUIT FOR THE REPLACEMENT OF THIS, I WAS NEVER NOTIFIED AND WANT THIS FIXED AT NO COST TO ME. AT APROX. 50 TO 60 MPH THE CAR ENGINES GOES WAY BEYOND THE PROPER RPM.

NHTSA ID

11153472

Incident

Nov 23, 2018

Mileage

62,000 mi

TL* THE CONTACT OWNS A 2004 MINI COOPER. THE CONTACT STATED THAT THE STEERING WHEEL WAS DIFFICULT TO TURN IN EITHER DIRECTION. THE ELECTRIC POWER STEERING WARNING INDICATOR WAS NOT ILLUMINATED. AN UNKNOWN DEALER WAS CONTACTED AND STATED THAT THE VEHICLE WAS NOT UNDER WARRANTY, AND WAS EXCLUDED FROM NHTSA CAMPAIGN NUMBER: 15V660000 (STEERING) AND NHTSA ACTION NUMBERS: EA11005 (STEERING) AND PE10038 (STEERING). THE MANUFACTURER WAS NOTIFIED AND DID NOT ASSIST. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE FAILURE MILEAGE WAS NOT AVAILABLE.

NHTSA ID

11141289

Incident

Aug 1, 2017

POWER STEERING HAS BEEN AN ISSUE OVER A YEAR OR TWO. NO TOTAL FAILURES BUT IT DOES NOT QUALIFY AS POWER STEERING. THE COOLING FAN DOES NOT WORK. STEERING IS NOT GOOD....FOR POWERED STEERING THAT IS. SLOW SPEED STEERING IS HORRENDOUS AND NON EXISTENT.

NHTSA ID

11129929

Incident

Jul 28, 2015

Mileage

20 mi

Cavity protection applied to underside of the hood is leaking out onto the wheel arch trim and grille.

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

MINI: DIFFERENT FAULTS ACTIVATES ENGINE MALFUNCTION AND OIL WARNING. *MA