2005 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 2005 Mini Cooper. The contact stated that there was water accumulated on the passenger's side front floorboard. The contact stated that the heater was causing some undisclosed issues. There were no warning lights illuminated. The contact stated that the failure was related to NHTSA Campaign Number: 23V337000 (Electrical System). The contact called the local dealer and was informed that the VIN was not included in the recall. The vehicle was diagnosed, and it was determined that the sunroof drain tubes were clogged, the drain tubes were cleared, and an undisclosed reprogramming was completed. The vehicle was repaired. The manufacturer was contacted and referred the contact to the NHTSA Hotline. The failure mileage was approximately 172,843.

NHTSA ID

11654543

Incident

Jan 1, 2022

Mileage

172,843 mi

The contact owns a 2005 Mini Cooper. The contact stated while driving 35 MPH, the steering wheel was difficult to turn. The vehicle lost power steering functionality. The contact stated that the failure was related to NHTSA Campaign Number: 15V660000 (Steering). The vehicle was taken to an independent mechanic, who determined that the power steering pump needed to be replaced. The vehicle was taken to the local dealer, but the vehicle was not diagnosed or repaired. The manufacturer was not contacted. The failure mileage was approximately 117,300.

NHTSA ID

11650688

Incident

Sep 1, 2024

Mileage

117,300 mi

The contact owns a 2005 Mini Coop S Hardtop. The contact stated that while the vehicle was parked and unoccupied, the vehicle alarm activated inadvertently and the contact noticed smoke coming from underneath the hood. The contact stated that he lifted the hood open and noticed fire coming from underneath the engine. The contact extinguished the fire with a fire extinguisher. There were no injuries sustained. The vehicle was towed to an independent mechanic; however, the vehicle was not diagnosed or repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 160,000.

NHTSA ID

11524398

Incident

May 24, 2023

Mileage

160,000 mi

The vehicle experienced a loss of power steering assist. The dealer was made aware of the failure; however, the vehicle was not repaired. The dealer informed me that there was no recall associated with the VIN. The failure is NHTSA Campaign Number: 15V660000 (Steering) however, the VIN was not included in the recall.

NHTSA ID

11516631

Incident

Feb 6, 2023

Mileage

99,000 mi

The contact owns a 2005 Mini Cooper. The contact stated that while driving at an undisclosed speed, the vehicle experienced a loss of power steering assist. The dealer was made aware of the failure; however, the vehicle was not diagnosed nor repaired. The dealer informed the contact that there was no recall associated with the VIN. The manufacturer was not made aware of the failure. The contact related the failure to NHTSA Campaign Number: 15V660000 (Steering) however, the VIN was not included in the recall. The failure mileage was approximately 167,000.

NHTSA ID

11472748

Incident

Jul 7, 2022

Mileage

167,000 mi

2005 Mini Cooper S has power steering whine, hard to steer the wheel. Very unsafe.

NHTSA ID

11433934

Incident

Sep 8, 2021

Driving at approximately 10-15 miles an hour entering a parking lot when I noticed flames coming out of the hood scoop of my 2005 Mini Cooper S. After brief inspection from my mechanic, it is believed to have been caused by the wiring harness for ABS or possibly the power steering unit since the fire originated from the rear/right hand side of the engine and those two components. I have a claim opened with USAA but during simple research, I have found tens, if not close to a hundred issues with similar characteristics. I know I am not the first R53 Mini Cooper (2002-2006 run) with this problem and this should be considered a hazard and public safety issue. I have included the link to many of the cases captured by the North American Motoring Association (a primarily North American Mini car association) which details 24 pages of these issues. https://www.northamericanmotoring.com/forums/stock-problems-issues/73527-spontaneous-engine-bay-fires.html?ispreloading=1

NHTSA ID

11432141

Incident

Sep 1, 2021

WHEN DRIVING VEHICLE TRANSMISSION SLIPS CAUSING A JERK REACTION IN THE VEHICLE AND THEN IT WILL RENEGADE CAUSING ANOTHER JERK REACTION IN THE VEHICLE AND MAKES GOING AND OR STOPPING UNPREDICTABLE. TURNING LEFT IS DANGEROUS AS THE CAR MAY NOT MOVE FORWARD AT A SPEED THAT IT SHOULD OR MAY JERK IN THE MIDDLE CAUSING THE VEHICLE TO STOP IN FRONT OF ONCOMING TRAFFIC. I HAVE HAD A MACHANIC CHANGE THE TRANSMISSION AND IT STILL DOES THE SAME THING. I HAVE CONTACTED THE MANUFACTURERS WHO INFORMED ME THAT THERE WERE NO RECALLS AND NOTHING THEY WOULD DO.

NHTSA ID

11397204

Incident

Feb 16, 2021

Mileage

1 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.

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:

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.

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