IllustrationPARKING ASSIST ALARM STOPPED WORKING COMPLETELY THEN THE NEXT TIME AS SOON AS THE VEHICLE WAS IN REVERSE THE ALARM SOUNDED AS THOUGH IMPACT WERE IMMINENT THOUGH NOTHING WAS BEHIND THE VEHICLE. ALARM CONTINUES TO SOUND WHENEVER THE MINI IS IN REVERSE. *TR
2004 Mini Cooper S
Owner reports · Recalls · Investigations
More warning signs than most Cooper S years
Owner complaints for the 2004 Mini Cooper S are substantially higher than the model-year median of 23.5.
About this comparison →How this year compares
Owner complaints by model year
Compare all Cooper S 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
120–25K
3425–50K
7250–75K
5675–100K
46100–150K
11150K+
231 reports with mileage · 16 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 210 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Electrical System. Review the 19 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Visibility. Review the 12 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
7 crash reports5 fire reports2 injury reports
Electrical System complaints
19 reportsTHE ELECTRIC POWER STEERING PUMP FAILED... SAW SMOKE COMING FROM ENGINE AREA, EVEN WHEN POWER TO ENGINE WAS SHUT OFF AND KEY REMOVED. AFTER SEVERAL ATTEMPTS TO RESTART VEHICLE AFTER TALKING WITH SERVICE MECHANIC, HE ADVISED TO "RESTART" CAR UNTIL THE POWER STEERING UNIT POSSIBLY TURNED BACK ON. AFTER 6 ATTEMPTS (APPOX 3 MINS APA…
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THE ELECTRIC POWER STEERING PUMP FAILED... SAW SMOKE COMING FROM ENGINE AREA, EVEN WHEN POWER TO ENGINE WAS SHUT OFF AND KEY REMOVED. AFTER SEVERAL ATTEMPTS TO RESTART VEHICLE AFTER TALKING WITH SERVICE MECHANIC, HE ADVISED TO "RESTART" CAR UNTIL THE POWER STEERING UNIT POSSIBLY TURNED BACK ON. AFTER 6 ATTEMPTS (APPOX 3 MINS APART), THE SYSTEM STARTED TO WORK AGAIN, BUT WITH A "STIFF & GRINDING" NOISE COMING FROM THE PUMP BEING TRANSMITTED THRU THE STEERING WHEEL. CAUSE OF FAILURE IS "POWER STEERING PUMP/FAN UNIT". VERY DANGEROUS, AS THIS HAPPENED AT SPEED ON FREEWAY, AND LOST ALMOST ALL CONTROL OF STEERING.
POWER STEERING FAILS. ON MULTIPLE OCCASIONS THE POWER STEERING HAS FAILED, BOTH WHILE DRIVING AS WELL AS AFTER JUST STARTING THE CAR. THE PROBLEM IS INTERMITTENT AND I SEE NO PATTERN TO IT'S OCCURRENCE. TYPICALLY IT IS REMEDIED BY TURNING OFF THE CAR AND RE-STARTING. THERE HAS BEEN A FEW OCCASIONS WHERE IT WILL SPUTTER IN A…
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POWER STEERING FAILS. ON MULTIPLE OCCASIONS THE POWER STEERING HAS FAILED, BOTH WHILE DRIVING AS WELL AS AFTER JUST STARTING THE CAR. THE PROBLEM IS INTERMITTENT AND I SEE NO PATTERN TO IT'S OCCURRENCE. TYPICALLY IT IS REMEDIED BY TURNING OFF THE CAR AND RE-STARTING. THERE HAS BEEN A FEW OCCASIONS WHERE IT WILL SPUTTER IN AND OUT BEFORE IT GOES OUT COMPLETELY BUT THE MOST COMMON OCCURRENCE IS WHEN I START THE CAR, THERE'S IS NO POWER STEERING.
MY CAR HAS HAD INTERMITTENT POWER FAILURE SINCE 2008, USUALLY LASTING A FEW DAYS. MORE RECENTLY MY POWER STEERING HAS BEEN OUT FOR THE PAST 2 MONTHS. TODAY IT STARTED WORKING ON MY WAY HOME FROM WORK BUT THE POWER STEERING FAN REMAINS ON AFTER I TURN THE CAR OFF. I HAD TO DISCONNECT THE BATTERY IN ORDER TO KEEP THE FAN OFF. CONS…
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MY CAR HAS HAD INTERMITTENT POWER FAILURE SINCE 2008, USUALLY LASTING A FEW DAYS. MORE RECENTLY MY POWER STEERING HAS BEEN OUT FOR THE PAST 2 MONTHS. TODAY IT STARTED WORKING ON MY WAY HOME FROM WORK BUT THE POWER STEERING FAN REMAINS ON AFTER I TURN THE CAR OFF. I HAD TO DISCONNECT THE BATTERY IN ORDER TO KEEP THE FAN OFF. CONSEQUENCES HAVE RESULTED IN NEAR ACCIDENTS ON THE HIGHWAY AND ROAD WHEN FAILURE OCCURS (FAILURES HAPPENED WHEN I HAVE GONE INTO TURNS). POWER STEERING PUMP AND FAN WILL NEED TO BE REPLACED. *TR
ON MY WAY UP DRIVEWAY I NOTICED A SHARP STINGING SENSATION IN THE LUMBAR OF MY BACK. FELT SORT OF LIKE AN "CONTINUOUS ELECTRIC SHOCK". I IMMEDIATELY ARCHED MY BACK AS A REACTION TO THE STING AND HAD TO STRAIGHTEN MY BACK IN ORDER TO CONTROL THE VEHICLE. WHEN STRAIGHTENING MY BACK I FELT SOMETHING HOT, VERY HOT THIS TIME LIKE SOM…
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ON MY WAY UP DRIVEWAY I NOTICED A SHARP STINGING SENSATION IN THE LUMBAR OF MY BACK. FELT SORT OF LIKE AN "CONTINUOUS ELECTRIC SHOCK". I IMMEDIATELY ARCHED MY BACK AS A REACTION TO THE STING AND HAD TO STRAIGHTEN MY BACK IN ORDER TO CONTROL THE VEHICLE. WHEN STRAIGHTENING MY BACK I FELT SOMETHING HOT, VERY HOT THIS TIME LIKE SOMETHING THAT WAS ON FIRE. I COULD NOT LONGER CONTROL THE VEHICLE GRABBED FOR THE HANDLE OPENED THE DOOR AND ROLLED OUT ONTO THE DRIVEWAY WHILE THE VEHICLE WAS MOVING. THE VEHICLE BUCKED AND STALLED OUT. I IMMEDIATELY LOOKED AT THE VEHICLE INTERIOR AND NOTICED THAT THE SEAT WAS SMOLDERING AND THERE WAS A HOLE THE SIZE OF A QUARTER BURNED THROUGH THE SEAT IN THE LUMBAR. IT WAS A 100 DEGREE DAY SO I WASN'T USING THE SEAT HEATER, NONETHELESS IT WAS ON, MALFUNCTIONED, CAUSED A FIRE WHICH RESULTED IN ME JUMPING OUT OF THE MOVING VEHICLE. I ALSO READ ONLINE ABOUT THIS HAPPENING TO ANOTHER 2004 MINI COOPER S "PASSENGER SEAT" AS WELL. *TR
WHEN THE WEATHER IS COLD, THE CENTER CONSOLE CONTROLS (HEAT, REAR DEFOGGER), THE HEADLIGHTS, FRONT/REAR WIPERS WILL NOT FUNCTION. WHEN CAR STARTS TO WARM UP, THOSE ITEMS WILL START WORKING WHEN THE STEERING WHEEL IS TURNED TO EITHER SIDE. WHEN CAR IS FULLY WARMED UP, WILL WORK MOST OF THE TIME UNLESS YOU HIT A BUMP. MINI SHOP S…
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WHEN THE WEATHER IS COLD, THE CENTER CONSOLE CONTROLS (HEAT, REAR DEFOGGER), THE HEADLIGHTS, FRONT/REAR WIPERS WILL NOT FUNCTION. WHEN CAR STARTS TO WARM UP, THOSE ITEMS WILL START WORKING WHEN THE STEERING WHEEL IS TURNED TO EITHER SIDE. WHEN CAR IS FULLY WARMED UP, WILL WORK MOST OF THE TIME UNLESS YOU HIT A BUMP. MINI SHOP SAID IT WAS A BAD COMPUTER - $800 TO FIX. ENGINE HAD AN OIL PLAN LEAK 2 YEARS AGO RESULTING IN MAJOR LOSS OF OIL. FIXED UNDER WARRANTY. WHEN GETTING ELECTRICAL PROBLEM FIXED, MINI SHOP FOUND 3 OIL LEAKS. TOTAL COST TO FIX WAS $3200. NOT NECESSARY TO GET THE FIX BUT NEED TO WATCH THE OIL LEVELS. *TR
A YEAR AFTER PURCHASING THE CAR, THE FRONT DRIVER'S WINDOW'S AUTOMATIC MOTOR WORKED INTERMITTENTLY, THEN WOULD NOT WORK AT ALL. THE DEALER FIXED IT SINCE IT HAPPENED TO BE UNDER FULL WARRANTY. TWO YEARS LATER, THE PASSENGER'S AUTOMATIC WINDOW MOTOR CEASED WORKING AT ALL. AT THE SAME TIME, THE DRIVER'S SIDE WINDOW WAS MAKING A SC…
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A YEAR AFTER PURCHASING THE CAR, THE FRONT DRIVER'S WINDOW'S AUTOMATIC MOTOR WORKED INTERMITTENTLY, THEN WOULD NOT WORK AT ALL. THE DEALER FIXED IT SINCE IT HAPPENED TO BE UNDER FULL WARRANTY. TWO YEARS LATER, THE PASSENGER'S AUTOMATIC WINDOW MOTOR CEASED WORKING AT ALL. AT THE SAME TIME, THE DRIVER'S SIDE WINDOW WAS MAKING A SCRATCHING SOUND AS IT WAS AUTOMATICALLY ROLLED UP /OR DOWN. I ONLY HAD A FEW MONTHS LEFT ON THE WARRANTY, AND THE DEALER WAS REQUIRED AGAIN TO REPLACE THE WINDOW MOTOR. I HAVE READ SEVERAL OTHER MINI OWNERS THAT HAD TO REPLACE AT LEAST ONE WINDOW MOTOR AS WELL, BUT AT THEIR OWN COST SINCE THE WARRANTY HAD RUN OUT. IF THIS IS A INCESSANT AND OBVIOUS DEFECT BY MINI COOPER, IT SHOULD BE RECALLED OR ADDRESSED IN A FAIR CONSUMER MANNER. *TR
I OWN A 2004 MINI COOPER S MODEL, WITH 39,000 MILES. THE CAR IS WELL CARED FOR. MY WARRANTY EXPIRED AT 30,000 AND I BEGAN RECEIVING ANNOYING CALLS AND LETTERS FROM MINI TO PURCHASE AN ADDITIONAL EXTENDED WARRANTY. I DID NOT, BELIEVING THAT SIMPLY MAINTAINING MY CAR PROPERLY WOULD TAKE CARE OF ANY FUTURE ISSUES. I TRUSTED B…
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I OWN A 2004 MINI COOPER S MODEL, WITH 39,000 MILES. THE CAR IS WELL CARED FOR. MY WARRANTY EXPIRED AT 30,000 AND I BEGAN RECEIVING ANNOYING CALLS AND LETTERS FROM MINI TO PURCHASE AN ADDITIONAL EXTENDED WARRANTY. I DID NOT, BELIEVING THAT SIMPLY MAINTAINING MY CAR PROPERLY WOULD TAKE CARE OF ANY FUTURE ISSUES. I TRUSTED BMW/MINI THAT THEY WOULD STAND BEHIND THEIR PRODUCT IF SOME UNUSUAL FAILURE OR BREAKDOWN OCCURRED. APPROXIMATELY ONE MONTH AGO MY POWER STEERING WOULD INTERMITTENTLY GO OUT. AT FIRST, ONLY AFTER STARTING THE CAR AND THEN IT STARTED OCCURRING WHILE DRIVING THE CAR. WE CHECKED THE POWER STEERING FLUID AND ALL WAS WELL. TOOK IT IN TO MY MECHANIC AND HE INFORMED ME THAT THE POWER STEERING PUMP NEEDED TO BE REPLACED. HE EXPLAINED THAT MINI HAD TOLD HIM "THEY" HAD BEEN EXPERIENCING A HIGH INSTANCES OF STEERING POWER PUMP FAILURES. HE ASKED IF THE POWER STEERING PUMP WAS ON THE RECALL LIST. "THEY" TOLD HIM NO AND EXPLAINED THAT THE PUMP WAS ELECTRICAL AND NOT MANUALLY THEREFORE IT WAS CONSIDERED WEAR AND TEAR. CREVIER MINI, WHERE I PURCHASED THE CAR TOLD ME IT WOULD COST $1100.00 TO REPLACE THE PUMP! MY MECHANIC TOLD ME HE WOULD REPLACE IT FOR $880.00. MY MECHANIC INFORMED ME THAT IN ORDER FOR HIM TO GET A POWER STEERING PUMP, HE NEEDED TO TURN MY OLD PUMP INTO THEM. CREVIER TOLD HIM THAT "THEY" WERE REBUIDLING THESE!.THEY COULD NOT KEEP ENOUGH OF THEM ON THE SHELVES. THIS IS A SCANDALOUS OUTRAGE, PARTICULARLY AFTER READING VARIOUS BLOGS AND COMPLAINTS ABOUT THE EXACT SAME PROBLEM THAT I AM EXPERIENCING WITH MY MINI. I SHOULD CONSIDER MYSELF LUCKY IN THAT MY CAR DID NOT CATCH FIRE, SINCE IT IS ALWAYS GARAGED, OR THAT I DID NOT KILL MYSELF OR HURT SOME INNOCENT PEOPLE BY THE PROBLEM OCCURRING ON A STEEP CURVEY GRADE WHILE DRIVING. ADDITIONAL PROBLEMS APPROXIMATELY SIX MONTHS AGO, MY DRIVER SIDE WINDOW STOPPED WORKING!! TOOK IT IN CREVIER WANTED $900 TO FIX THE PROBLEM, AGAIN STATED WEAR AND TEAR!! MY MECHANIC CHARGED ME $400.00. *TR
I WAS PARKED ONE AFTER NOON LOOKING UNDER THE HOOD AND I HEARD A CRACKLING SOUND COMING FORM THE ABS PUMP. THERE WAS A SMALL PUFF OF SMOKE AND THEN THE SOUND STOPPED. AT THIS POINT I WENT ABOUT MY BUSINESS AND RETURNED TO MY 2004 MINI COOPER S AND THE ABS/TRACTION CONTROL LIGHT WERE OUT. A FEW DAYS LATER I TOOK THE VEHICLE TO TH…
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I WAS PARKED ONE AFTER NOON LOOKING UNDER THE HOOD AND I HEARD A CRACKLING SOUND COMING FORM THE ABS PUMP. THERE WAS A SMALL PUFF OF SMOKE AND THEN THE SOUND STOPPED. AT THIS POINT I WENT ABOUT MY BUSINESS AND RETURNED TO MY 2004 MINI COOPER S AND THE ABS/TRACTION CONTROL LIGHT WERE OUT. A FEW DAYS LATER I TOOK THE VEHICLE TO THE BMW DEALER AND AFTER A FEW TESTS THEY DETERMINED IT WAS JUST BAD FUSES. A WEEK HAS PAST AND I HAVE HAD NO OTHER PROBLEMS. *TR
Official recalls
215V660000 · Steering:electric Power Assist System
Oct 15, 2015
BMW of North America, LLC (BMW) is recalling certain model year 2002-2005 MINI Cooper and Cooper S vehicles and 2005 Cooper and Cooper S Convertible vehicles. The affected vehicles may experience temporary or permanent loss of the electro-hydraulic steering assistance.
Consequence & remedy
Consequence: If the vehicle experiences a loss of power steering assist, extra steering effort will be required at lower speeds, potentially increasing the risk of a vehicle crash.
Remedy: MINI will notify owners, and dealers will inspect the electro-hydraulic power steering system, replacing the components and wiring, as necessary, free of charge. Interim notices were mailed to owners on December 10, 2015. Owners will receive a second notice when remedy parts become available. Owners may contact MINI customer service at 1-866-825-1525.
04V348000 · Tires:pressure Monitoring And Regulating Systems
Jul 12, 2004
ON CERTAIN PASSENGER VEHICLES, THE FLAT TIRE MONITORING SYSTEM HAS NOT BEEN CORRECTLY PROGRAMMED. IN THE EVENT OF A FLAT TIRE, AN AUDIBLE SIGNAL WILL NOT SOUND TO ALERT THE DRIVER TO A FLAT TIRE.
Consequence & remedy
Consequence: DUE TO THE LACK OF AN AUDIBLE SIGNAL, THE DRIVER MAY NOT BE AWARE OF A FLAT TIRE, WHICH COULD INCREASE THE RISK OF A CRASH.
Remedy: DEALERS WILL REPROGRAM THE VEHICLE'S SOFTWARE IN ORDER TO ACTUATE THE FLAT TIRE MONITORING SYSTEM'S AUDIBLE SIGNAL. THE RECALL BEGAN OCTOBER 13, 2004. OWNERS SHOULD CONTACT MINI CUSTOMER RELATIONS AT 1-866-275-6464.
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
2EA11005 · 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
PE10038 · Loss Of Power Steering Assist
Opened Sep 24, 2010 · Closed May 10, 2011
Status: closed (inferred from source dates) · Steering; Steering:electric Power Assist System; Steering:hydraulic Power Assist System; Steering:hydraulic Power Assist:pump
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).
Additional source detail variants (4)
Steering
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).
Steering:electric Power Assist System
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).
Steering:hydraulic Power Assist:pump
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).
Steering:hydraulic Power Assist System
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).