IllustrationPASSENGER AIRBAG LIGHT HAS BEEN ON SINCE 2013. MECHANICS TELL ME THAT IT IS A WEIGHT-SENSING MAT ON THE SEAT. MINI RECALLED 2005 MINI'S BUT THIS ONE IS NOT INCLUDED IN THE RECALL. THIS IS A VERY COMMON PROBLEM WITH THIS YEAR FOR THIS CAR.
2005 Mini Cooper S Convertible
Owner reports · Recalls · Investigations
Limited comparison data
There is not enough comparable history to draw a useful model-year comparison.
About this comparison →How this year compares
Owner complaints by model year
Compare all Cooper S Convertible years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
20–25K
1625–50K
1650–75K
1375–100K
8100–150K
0150K+
55 reports with mileage · 6 unknown
NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.
What to inspect
Issues worth paying extra attention to based on owner reports.
- Steering. Review the 37 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Air Bags. Review the 15 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Power Train. Review the 6 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
0 crash reports4 fire reports0 injury reports
Air Bags complaints
15 reportsTL* THE CONTACT OWNS A 2005 MINI COOPER S CONVERTIBLE. THE CONTACT RECEIVED A NOTIFICATION FOR NHTSA CAMPAIGN NUMBER: 15V205000 (AIR BAGS); HOWEVER, THE PART TO DO THE REPAIR WAS UNAVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. THE MANUFACTURER WAS MADE AWARE OF TH…
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TL* THE CONTACT OWNS A 2005 MINI COOPER S CONVERTIBLE. THE CONTACT RECEIVED A NOTIFICATION FOR NHTSA CAMPAIGN NUMBER: 15V205000 (AIR BAGS); HOWEVER, THE PART TO DO THE REPAIR WAS UNAVAILABLE. 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 NOT EXPERIENCED A FAILURE.
NOTIFIED THAT MINI WOULD RECALL DUE TO FAULTY SENSOR FOR AIRBAG ON MAY 1. NOW 4 MONTHS LATER, AND STILL NO RECALL. MINI SAYS THEY ARE GATHERING DATA ON THE AFFECTED CARS, NO INFO ON WHEN RECALL AND REPAIR WILL ACTUALLY HAPPEN.
ON APRIL 20, 2015, I TOOK MY 2005 MINI S CONVERTIBLE TO MINI OF FAIRFIELD COUNTY IN DARIEN, CT BECAUSE THE AIR BAG LIGHT WAS ON. I RECEIVED A VERBAL QUOTE OF APPROXIMATELY $1200 TO REPAIR. LATER THAT DAY I RECEIVED AN EMAIL FROM THE SHOP FOREMAN STATING THAT MINI WAS AWARE OF AN ISSUE WITH THE PASSENGER SEAT SENSOR AND THAT MI…
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ON APRIL 20, 2015, I TOOK MY 2005 MINI S CONVERTIBLE TO MINI OF FAIRFIELD COUNTY IN DARIEN, CT BECAUSE THE AIR BAG LIGHT WAS ON. I RECEIVED A VERBAL QUOTE OF APPROXIMATELY $1200 TO REPAIR. LATER THAT DAY I RECEIVED AN EMAIL FROM THE SHOP FOREMAN STATING THAT MINI WAS AWARE OF AN ISSUE WITH THE PASSENGER SEAT SENSOR AND THAT MINI WAS LOOKING INTO A COURSE OF ACTION. A FEW DAYS LATER THE PRESS REPORTED THAT A RECALL WAS BEING DONE FOR THIS ISSUE AND I CALLED AGAIN, WHEN I WAS TOLD THAT A LETTER WOULD COME FROM MINI WITH DETAILS. SOMETIME BETWEEN THEN AND JUNE 15, I RECEIVED A LETTER (DATED "JUNE 2015") STATING THAT A RECALL WAS GOING TO BE ISSUED, AND I SHOULD NOT CARRY PASSENGERS IF THE LIGHT WAS ON (IT HAD BEEN ON SINCE APRIL), AND AGAIN CALLED MINI OF FAIRFIELD COUNTY, WHERE THEY REITERATED THE INFO IN THE LETTER THAT I WOULD HAVE TO WAIT FOR YET ANOTHER LETTER. I CALLED MINI CUSTOMER CARE BOTH ON JUNE 15 AND AUGUST 25 TO REQUEST INFORMATION ON THE TIMING, AND THEY WERE UNABLE TO PROVIDE ANY INFORMATION BEYOND WHAT THE DEALER TOLD ME. IT IS NOW AUGUST 25, AND OVER FOUR MONTHS THAT I'VE BEEN UNABLE TO SAFELY CARRY A PASSENGER IN THIS VEHICLE. I FEEL THAT THIS MEETS THE STANDARD NOTED IN THE RECALL LETTER "IF YOUR MINI DEALER IS UNABLE TO REMEDY THE DEFECT WITHOUT CHARGE OR WITHIN A REASONABLE AMOUNT OF TIME", ESPECIALLY WHEN I WAS GIVEN A VERBAL QUOTE IN APRIL TO FIX THE ISSUE. MINI HAS ALSO DECLINED TO PROVIDE A LOANER VEHICLE WHILE MINE IS DISABLED. I REQUEST THAT NHTSA INVESTIGATE WHETHER MINI INTENDS TO PROPERLY CARRY OUT THIS RECALL (15V-205).
THE PASSENGER SIDE AIR BAG SENSOR TURNS OFF EVEN THOUGH A PASSENGER IS IN THE SEAT. THIS ISSUE SHOULD BE COVERED BY THE LATEST RECALL NOTICE BUT MINI USA HAS NOT INCLUDED MY VEHICLE. *TR
THE PASSENGER DETECTOR ON MY PASSENGER SEAT HAS FAILED. THIS IS A KNOWN ISSUE IN MINI COOPERS AND BMWS OF THIS AGE. THE FIX IS COMPLETE $1500 SEAT REPLACEMENT AT THE DEALER. BMW HAS ALREADY RECALLED THE PARTS FOR ALL THE BMWS WHERE THIS OCCURS, BUT NOT THE MINIS. *TR
PASSENGER SEAT OCCUPANCY SENSOR/MAT FAILS WHICH RESULTS IN THE PASSENGER SEAT AIRBAG BEING DISABLED. THIS IS DANGEROUS BECAUSE THE AIRBAG WILL NOT DEPLOY FOR THE PASSENGER IF THERE IS AN ACCIDENT. THIS IS A COMMON PROBLEM THAT COSTS OVER $1300 TO FIX BUT MINI WILL NOT ISSUE A WARRANTY CLAIM FOR IT. THERE ARE THOUSANDS OF OTHER V…
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PASSENGER SEAT OCCUPANCY SENSOR/MAT FAILS WHICH RESULTS IN THE PASSENGER SEAT AIRBAG BEING DISABLED. THIS IS DANGEROUS BECAUSE THE AIRBAG WILL NOT DEPLOY FOR THE PASSENGER IF THERE IS AN ACCIDENT. THIS IS A COMMON PROBLEM THAT COSTS OVER $1300 TO FIX BUT MINI WILL NOT ISSUE A WARRANTY CLAIM FOR IT. THERE ARE THOUSANDS OF OTHER VEHICLES THAT HAVE HAD THIS SAME PROBLEM BUT MINI WILL NOT STAND BEHIND THEIR PRODUCT. THIS IS THE EXACT SAME PROBLEM AS THE RECALL ISSUED BY BMW (NHTSA CAMPAIGN 13V564000). *TR
SAW ON THE WEB THAT MINI RECALLED AND THEN EXTENDED WARRANTY RECALL ON AN AIRBAG MALFUNCTION. THE LIGHT CAME ON A FEW DAYS AGO, BUT I CAN NOT FIND ANY INFORMATION AS TO THE TRUTH IN THAT STATEMENT. SUPPOSEDLY 10 YEARS OR 150,000 MILES. *TR
AIRBAG SENSOR LIGHT IS ON, INDICATING A PROBLEM WITH THE PASSENGER AIRBAG. THIS IS A COMMON PROBLEM WITH MINIS AND CERTAIN BMWS. MINI HAS VOLUNTARILY REPAIRED THE DEFECT IN SOME VEHICLES BUT IS REFUSING TO REPAIR OTHERS. MINI TOLD ME TO TAKE IT TO A DEALER, PAY FOR A DIAGNOSTIC AND THEY'D THINK ABOUT A REPAIR. I HAVE NO FAIT…
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AIRBAG SENSOR LIGHT IS ON, INDICATING A PROBLEM WITH THE PASSENGER AIRBAG. THIS IS A COMMON PROBLEM WITH MINIS AND CERTAIN BMWS. MINI HAS VOLUNTARILY REPAIRED THE DEFECT IN SOME VEHICLES BUT IS REFUSING TO REPAIR OTHERS. MINI TOLD ME TO TAKE IT TO A DEALER, PAY FOR A DIAGNOSTIC AND THEY'D THINK ABOUT A REPAIR. I HAVE NO FAITH IN THEIR WILLINGNESS TO PROVIDE A REPAIR SINCE ETHER HAVE REFUSED THE REPAIR REPEATEDLY TO OTHER CONSUMERS. THIS IS A COMMON SAFETY ISSUE, AND APPEARS TO CLEARLY BE A DEFECT RATHER THAN AN EXPECTED WEARING OUT OF THE VEHICLE. *TT
I WAS TOLD THE FOLLOWING ABOUT MY PASSENGER AIRBAG SYSTEM. BASICALLY THE COMPUTER FAILED AND I HAD A CRACK IN THE PASSENGER SEAT SENSOR. THIS CAR HAS ONLY 32,000 MILES AND WAS MOSTLY DRIVEN WITH NO ONE IN THE PASSENGER SEAT. THIS SHOULD NOT HAVE FAILED WITH SUCH MINIMAL USE.: REPLACE MRS MODULE AND PROGRAM,ENCODE (MRS MODU…
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I WAS TOLD THE FOLLOWING ABOUT MY PASSENGER AIRBAG SYSTEM. BASICALLY THE COMPUTER FAILED AND I HAD A CRACK IN THE PASSENGER SEAT SENSOR. THIS CAR HAS ONLY 32,000 MILES AND WAS MOSTLY DRIVEN WITH NO ONE IN THE PASSENGER SEAT. THIS SHOULD NOT HAVE FAILED WITH SUCH MINIMAL USE.: REPLACE MRS MODULE AND PROGRAM,ENCODE (MRS MODULE FAILURE, INTERNAL SHORT CIRCUIT) FAIL $774.06 REPLACE PASSENGER SEAT OCCUPANCY MAT (PASSENGER SEAT OCCUPANCY MAT HAS MICRO CRACK ON MAT FAULT 0071)FAIL $874.55. *TR
Official recalls
115V205000 · Air Bags:frontal
Apr 6, 2015
BMW of North America, LLC (BMW) is recalling certain model year 2005-2006 MINI Cooper and Cooper S vehicles manufactured January 5, 2005, to November 28, 2006, and 2005-2008 MINI Cooper Convertible and Cooper S Convertible vehicles manufactured January 5, 2005, to July 31, 2008. Due to manufacturing, installation, and exposure issues, the front passenger seat occupant detection mat may not function properly and, as a result, the front passenger air bag may not deploy in a crash.
Consequence & remedy
Consequence: An improperly functioning mat may cause the passenger frontal air bag to be inactive when the seat is occupied, and in the event of a crash, the air bag will not deploy, increasing the passenger's risk of injury.
Remedy: MINI will notify owners, and dealers will replace the front passenger seat occupant detection mat, free of charge. The recall began on October 12, 2015. Owners may contact MINI customer service at 1-866-825-1525.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
1EA11005 · Loss Of Power Steering Assist
Opened May 4, 2011 · Closed Jan 5, 2016
Status: closed (inferred from source dates) · Steering; Steering:electric Power Assist System; Steering:hydraulic Power Assist System; Steering:hydraulic Power Assist:pump
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
Additional source detail variants (4)
Steering
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
Steering:electric Power Assist System
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
Steering:hydraulic Power Assist:pump
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
Steering:hydraulic Power Assist System
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