IllustrationTHE SPARKPLUG HAS BLOWN COMPLETELY OUT THE HEAD OF MY 2003 MINI COOPER, I WENT ON LINE AND FOUND OUT THAT THIS IS BECOMING A COMMON PROBLEM. *TR
2003 Mini Cooper
Owner reports · Recalls · Investigations
More warning signs than most Cooper years
Owner complaints for the 2003 Mini Cooper are substantially higher than the model-year median of 40.5.
About this comparison →How this year compares
Owner complaints by model year
Compare all Cooper 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
200–25K
3125–50K
9050–75K
7475–100K
57100–150K
9150K+
281 reports with mileage · 39 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 159 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Power Train. Review the 89 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Electrical System. Review the 26 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
3 crash reports27 fire reports3 injury reports
Equipment complaints
7 reportsMY TRANSMISSION FAILED ON MY MINI-COOPER ONCE WHEN IT WAS IN WARRANTY AND I HAD TO PAY TO HAVE IT FIXED, ONCE AGAIN, AND IT WAS JUST OUT OF WARRANTY AND I PAID 3000$ TO HAVE IT FIXED AND ONCE AGAIN WHEN THE 2ND TRANSMISSION WAS IN WARRANTY AND MINICOOPER FIXED IT. THIS CAR WAS A LEMON AND MINI NEVER ACCEPTED RESPONSIBILITY FOR …
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MY TRANSMISSION FAILED ON MY MINI-COOPER ONCE WHEN IT WAS IN WARRANTY AND I HAD TO PAY TO HAVE IT FIXED, ONCE AGAIN, AND IT WAS JUST OUT OF WARRANTY AND I PAID 3000$ TO HAVE IT FIXED AND ONCE AGAIN WHEN THE 2ND TRANSMISSION WAS IN WARRANTY AND MINICOOPER FIXED IT. THIS CAR WAS A LEMON AND MINI NEVER ACCEPTED RESPONSIBILITY FOR THE DEFECTIVE TRANSMISSION PROBLEMS. *TR
SUDDEN UNEXPECTED FAILURE. CVT TRANSMISSION (AUTOMATIC) IN 2003 MINI COOPER. FIRST ONE WAS UNDER WARRANTY. THE SECOND TIME THEY TOLD ME THEY WOULD SELL ME ANOTHER CAR. THE CAR SOLD FOR $22K NEW, TRANSMISSION COSTS $8500 TO REPLACE. SO THAT'S $17000 WORTH OF TRANSMISSIONS 4 YEARS (ITS BEEN SITTING FOR THE LAST YEAR WHILE I STILL …
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SUDDEN UNEXPECTED FAILURE. CVT TRANSMISSION (AUTOMATIC) IN 2003 MINI COOPER. FIRST ONE WAS UNDER WARRANTY. THE SECOND TIME THEY TOLD ME THEY WOULD SELL ME ANOTHER CAR. THE CAR SOLD FOR $22K NEW, TRANSMISSION COSTS $8500 TO REPLACE. SO THAT'S $17000 WORTH OF TRANSMISSIONS 4 YEARS (ITS BEEN SITTING FOR THE LAST YEAR WHILE I STILL HAVE TO MAKE PAYMENTS). I DON'T THINK THEIR IDEA OF BUYING ANOTHER CAR TO REPLACE MY TRANSMISSION WAS A GOOD IDEA. *TR
MY CAR WAS BROUGHT INTO THE DEALERSHIP FOR AN OIL CHANGE AND REAR BRAKE REPAIR ON TUESDAY (JUNE 26, 2007). WEDNESDAY EVENING (JUNE 27, 2007) THE CAR WAS DRIVEN 15 MINUTES, PARKED FOR ALMOST AN HOUR, THEN DRIVEN A MERE 30 SECONDS TO CHANGE TO A DIFFERENT PARKING SPOT. WALKED AWAY FOR A MINUTE AND NOTICED SMOKE COMING FROM THE F…
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MY CAR WAS BROUGHT INTO THE DEALERSHIP FOR AN OIL CHANGE AND REAR BRAKE REPAIR ON TUESDAY (JUNE 26, 2007). WEDNESDAY EVENING (JUNE 27, 2007) THE CAR WAS DRIVEN 15 MINUTES, PARKED FOR ALMOST AN HOUR, THEN DRIVEN A MERE 30 SECONDS TO CHANGE TO A DIFFERENT PARKING SPOT. WALKED AWAY FOR A MINUTE AND NOTICED SMOKE COMING FROM THE FRONT OF THE CAR. UPON OPENING THE BONNET, THERE WAS FLAMES COMING FROM THE UNDERSIDE OF THE ENGINE. THE FIRST ATTEMPT AT USING A FIRE EXTINGUISHER TEMPORARILY PUT OUT THE FIRE, THEN IT RE-IGNITED WHICH THE FIRE DEPARTMENT WAS THEN CALLED TO PUT IT OUT SAFELY. THE CAR WAS BROUGHT THE NEXT MORNING (JUNE 28, 2007) TO THE DEALERSHIP AND WAS NOT LOOKED AT UNTIL THE NEXT DAY (JUNE 29, 2009). THE DIAGNOSIS WAS THE STEERING PUMP FAILED, UPON WHICH IT OVERHEATS CAUSING THE FIRE. THE FIRE THEN DAMAGED THE LOOM (HARNESS, OR MAIN WIRING FOR THE VEHICLE), WHICH ALSO RUINED THE BATTERY. PRIOR TO THE FIRE, THERE WERE NO SIGNS THAT THE STEERING WAS FAILING, NOR ANY INDICATION THAT THERE WAS ANY OTHER POSSIBLE ELECTRICAL PROBLEMS. CAR MILEAGE WAS AT 65,500 AT THE TIME IT WAS BROUGHT TO THE DEALER, AND ABOUT 65,525 MILES AT THE TIME OF THE INCIDENT. NOTHING WILL BE DONE UNTIL THE INSURANCE AGENTS FROM BOTH THE CONSUMER AND DEALERSHIP ASSESS THE DAMAGES. *TR
2003 MINI COOPER WINDSHIELD FAILURE. SPONTANEOUS CRACK ALTHOUGH DEALER INSISTS IT WAS A PIN HOLE SIZED HOLE THAT CAUSED IT. REFUSED TO COVER UNDER WARRANTY. 2ND TIME IT'S HAPPENED AND WAS COVERED FIRST TIME UNDER WARRANTY. APPARENTLY HAPPENS VERY REGULARLY TO MINI AND AT $1078. COMPLETE...THIS JUST ISN'T RIGHT. *JB
THIS CAR IS LESS THAN A YEAR OLD. SO FAR THE AIR BAG INDICATOR LIGHT MALFUNCTIONED, THE RADIO WAS REPLACED, THE PASSENGER WINDOW MOTOR WAS REPLACED, THE NAVIGATION SYSTEM DISPLAY IS ABOUT TO BE REPLACED, AND TWO RED MARKS ON THE TAKOMETER NO LONGER LIGHT UP.*AK
WINDSHIELDS ON MINI COOPERS CRACKING,CHIPPING EASY AND FREQUENTLY. I HAVE HAD FOUR WINDSHIELDS REPLACES IN THE LAST 8 MONTHS. 2 COVERED UNDER WARRANTEE FOR STRESS RELATED CRACKS AND TWO DUE TO SMALL ROCK STRIKES. I HAVE NEVE BEEN THRU WINDSHIELDS LIKE THIS BEFORE AND FEEL THAT THE CONSTRUCTION AND DESIGN OF THE MINI WINDSHIELD …
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WINDSHIELDS ON MINI COOPERS CRACKING,CHIPPING EASY AND FREQUENTLY. I HAVE HAD FOUR WINDSHIELDS REPLACES IN THE LAST 8 MONTHS. 2 COVERED UNDER WARRANTEE FOR STRESS RELATED CRACKS AND TWO DUE TO SMALL ROCK STRIKES. I HAVE NEVE BEEN THRU WINDSHIELDS LIKE THIS BEFORE AND FEEL THAT THE CONSTRUCTION AND DESIGN OF THE MINI WINDSHIELD MAKES IT SUBSTANDARD IN PROTECTION.*AK
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.
03V086000 · Suspension:rear:shock Absorber
Mar 10, 2003
ON CERTAIN VEHICLES, THE LOWER SCREW CONNECTION OF THE REAR STRUTS TO THE CHASSIS MAY FAIL. THE HEAD (TOP) OF THE SCREW SECURING THIS CONNECTION MAY BREAK. THE REMAINING PORTION OF THE SCREW WILL STILL HOLD THE STRUT IN PLACE.
Consequence & remedy
Consequence: IF LEFT UNATTENDED OVER A PERIOD OF TIME, AND DEPENDING ON DRIVING CONDITIONS, THE REMAINING PORTION OF THE SCREW MAY BREAK. IF IT BROKE, THE CHASSIS WOULD LEAN DIRECTLY ON THE TIRE DIMINISHING THE DRIVER'S ABILITY TO CONTROL THE VEHICLE, INCREASING THE RISK OF A CRASH.
Remedy: DEALERS WILL REPLACE THE LOWER SCREW CONNECTION OF THE REAR STRUTS. OWNER NOTIFICATION BEGAN APRIL 7, 2003. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT BMW AT 1-800-831-1117.
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
5EA11005 · 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
EA07011 · Engine Compartment Fire
Opened Aug 14, 2007 · Closed Aug 13, 2008
Status: closed (inferred from source dates) · Steering:electric Power Assist System; Steering:hydraulic Power Assist System; Steering:hydraulic Power Assist:hose, Piping, And Connections; Steering:hydraulic Power Assist:pump
THE OFFICE OF DEFECTS INVESTIGATION (ODI) ANALYZED CONSUMER COMPLAINTS TO BMW OF NORTH AMERICA, LLC (BMW)AND TO ODI THAT ALLEGED FAILURES OF THE ELECTROHYDRAULIC POWER STEERING (EHPS) USED IN MODEL YEAR 2002 THROUGH 2003 MINI COOPER VEHICLES.THE ANALYSIS DETERMINED THAT 43 OF THE 52 (83%) REPORTS WERE RELATED TO ALLEGATIONS OF POWER STEERING LOSS AND 9 (17%) WERE RELATED TO ALLEGATIONS OF ENGINE COMPARTMENT FIRES. ALTHOUGH SOME OF THE REPORTS ALLEGING FIRES NOTE SMALL FLAMES WERE VISIBLE IN THE ENGINE COMPARTMENT, ANALYSIS OF THE DAMAGE CAUSED BY THESE FAILURES INDICATES THAT EVEN THE MOST SEVERE INCIDENTS WERE LIMITED TO LOCALIZED THERMAL DAMAGE TO THE EHPS ELECTRICAL CONNECTIONS AND WIRING INSULATION.NONE OF THE COMPLAINTS ALLEGING LOSS OF POWER ASSISTED STEERING INDICATED THAT THE INCREASED EFFORT RESULTED IN A CRASH OR LOSS OF VEHICLE CONTROL. A SAFETY-RELATED DEFECT TREND HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED. ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST. THE AGENCY WILL MONITOR THIS ISSUE AND RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY CIRCUMSTANCES.SEE DOCUMENT FILE FOR ADDITIONAL INFORMATION REGARDING THIS RESUME.
Additional source detail variants (4)
Steering:electric Power Assist System
THE OFFICE OF DEFECTS INVESTIGATION (ODI) ANALYZED CONSUMER COMPLAINTS TO BMW OF NORTH AMERICA, LLC (BMW)AND TO ODI THAT ALLEGED FAILURES OF THE ELECTROHYDRAULIC POWER STEERING (EHPS) USED IN MODEL YEAR 2002 THROUGH 2003 MINI COOPER VEHICLES.THE ANALYSIS DETERMINED THAT 43 OF THE 52 (83%) REPORTS WERE RELATED TO ALLEGATIONS OF POWER STEERING LOSS AND 9 (17%) WERE RELATED TO ALLEGATIONS OF ENGINE COMPARTMENT FIRES. ALTHOUGH SOME OF THE REPORTS ALLEGING FIRES NOTE SMALL FLAMES WERE VISIBLE IN THE ENGINE COMPARTMENT, ANALYSIS OF THE DAMAGE CAUSED BY THESE FAILURES INDICATES THAT EVEN THE MOST SEVERE INCIDENTS WERE LIMITED TO LOCALIZED THERMAL DAMAGE TO THE EHPS ELECTRICAL CONNECTIONS AND WIRING INSULATION.NONE OF THE COMPLAINTS ALLEGING LOSS OF POWER ASSISTED STEERING INDICATED THAT THE INCREASED EFFORT RESULTED IN A CRASH OR LOSS OF VEHICLE CONTROL. A SAFETY-RELATED DEFECT TREND HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED. ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST. THE AGENCY WILL MONITOR THIS ISSUE AND RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY CIRCUMSTANCES.SEE DOCUMENT FILE FOR ADDITIONAL INFORMATION REGARDING THIS RESUME.
Steering:hydraulic Power Assist:hose, Piping, And Connections
THE OFFICE OF DEFECTS INVESTIGATION (ODI) ANALYZED CONSUMER COMPLAINTS TO BMW OF NORTH AMERICA, LLC (BMW)AND TO ODI THAT ALLEGED FAILURES OF THE ELECTROHYDRAULIC POWER STEERING (EHPS) USED IN MODEL YEAR 2002 THROUGH 2003 MINI COOPER VEHICLES.THE ANALYSIS DETERMINED THAT 43 OF THE 52 (83%) REPORTS WERE RELATED TO ALLEGATIONS OF POWER STEERING LOSS AND 9 (17%) WERE RELATED TO ALLEGATIONS OF ENGINE COMPARTMENT FIRES. ALTHOUGH SOME OF THE REPORTS ALLEGING FIRES NOTE SMALL FLAMES WERE VISIBLE IN THE ENGINE COMPARTMENT, ANALYSIS OF THE DAMAGE CAUSED BY THESE FAILURES INDICATES THAT EVEN THE MOST SEVERE INCIDENTS WERE LIMITED TO LOCALIZED THERMAL DAMAGE TO THE EHPS ELECTRICAL CONNECTIONS AND WIRING INSULATION.NONE OF THE COMPLAINTS ALLEGING LOSS OF POWER ASSISTED STEERING INDICATED THAT THE INCREASED EFFORT RESULTED IN A CRASH OR LOSS OF VEHICLE CONTROL. A SAFETY-RELATED DEFECT TREND HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED. ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST. THE AGENCY WILL MONITOR THIS ISSUE AND RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY CIRCUMSTANCES.SEE DOCUMENT FILE FOR ADDITIONAL INFORMATION REGARDING THIS RESUME.
Steering:hydraulic Power Assist:pump
THE OFFICE OF DEFECTS INVESTIGATION (ODI) ANALYZED CONSUMER COMPLAINTS TO BMW OF NORTH AMERICA, LLC (BMW)AND TO ODI THAT ALLEGED FAILURES OF THE ELECTROHYDRAULIC POWER STEERING (EHPS) USED IN MODEL YEAR 2002 THROUGH 2003 MINI COOPER VEHICLES.THE ANALYSIS DETERMINED THAT 43 OF THE 52 (83%) REPORTS WERE RELATED TO ALLEGATIONS OF POWER STEERING LOSS AND 9 (17%) WERE RELATED TO ALLEGATIONS OF ENGINE COMPARTMENT FIRES. ALTHOUGH SOME OF THE REPORTS ALLEGING FIRES NOTE SMALL FLAMES WERE VISIBLE IN THE ENGINE COMPARTMENT, ANALYSIS OF THE DAMAGE CAUSED BY THESE FAILURES INDICATES THAT EVEN THE MOST SEVERE INCIDENTS WERE LIMITED TO LOCALIZED THERMAL DAMAGE TO THE EHPS ELECTRICAL CONNECTIONS AND WIRING INSULATION.NONE OF THE COMPLAINTS ALLEGING LOSS OF POWER ASSISTED STEERING INDICATED THAT THE INCREASED EFFORT RESULTED IN A CRASH OR LOSS OF VEHICLE CONTROL. A SAFETY-RELATED DEFECT TREND HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED. ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST. THE AGENCY WILL MONITOR THIS ISSUE AND RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY CIRCUMSTANCES.SEE DOCUMENT FILE FOR ADDITIONAL INFORMATION REGARDING THIS RESUME.
Steering:hydraulic Power Assist System
THE OFFICE OF DEFECTS INVESTIGATION (ODI) ANALYZED CONSUMER COMPLAINTS TO BMW OF NORTH AMERICA, LLC (BMW)AND TO ODI THAT ALLEGED FAILURES OF THE ELECTROHYDRAULIC POWER STEERING (EHPS) USED IN MODEL YEAR 2002 THROUGH 2003 MINI COOPER VEHICLES.THE ANALYSIS DETERMINED THAT 43 OF THE 52 (83%) REPORTS WERE RELATED TO ALLEGATIONS OF POWER STEERING LOSS AND 9 (17%) WERE RELATED TO ALLEGATIONS OF ENGINE COMPARTMENT FIRES. ALTHOUGH SOME OF THE REPORTS ALLEGING FIRES NOTE SMALL FLAMES WERE VISIBLE IN THE ENGINE COMPARTMENT, ANALYSIS OF THE DAMAGE CAUSED BY THESE FAILURES INDICATES THAT EVEN THE MOST SEVERE INCIDENTS WERE LIMITED TO LOCALIZED THERMAL DAMAGE TO THE EHPS ELECTRICAL CONNECTIONS AND WIRING INSULATION.NONE OF THE COMPLAINTS ALLEGING LOSS OF POWER ASSISTED STEERING INDICATED THAT THE INCREASED EFFORT RESULTED IN A CRASH OR LOSS OF VEHICLE CONTROL. A SAFETY-RELATED DEFECT TREND HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED. ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST. THE AGENCY WILL MONITOR THIS ISSUE AND RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY CIRCUMSTANCES.SEE DOCUMENT FILE FOR ADDITIONAL INFORMATION REGARDING THIS RESUME.
PE07022 · Engine Compartment Fire
Opened Apr 19, 2007 · Closed Aug 15, 2007
Status: closed (inferred from source dates) · Steering:electric Power Assist System; Steering:hydraulic Power Assist System; Steering:hydraulic Power Assist:hose, Piping, And Connections; Steering:hydraulic Power Assist:pump
IN RESPONSE TO AN INFORMATION REQUEST (IR) LETTER SENT BY THE OFFICE OF DEFECTS INVESTIGATION (ODI), BMW STATED THAT THE CAUSE OF THE ALLEGED DEFECT IS AN INSUFFICIENT SEAL OF THE GROUND CABLE OF THE POWER STEERING PUMP AT ITS ATTACHMENT TO THE CHASSIS.WATER INGRESS CAN OCCUR AND THE WATER CAN TRAVEL ALONG THE POWER STEERING PUMP POWER CABLE AND COME IN CONTACT WITH THE POWER STEERING PUMP POWER CABLE CONNECTOR.THE CONNECTOR CAN THEN CORRODE AND A HIGH THERMAL LOAD CONDITION CAN OCCUR.ACCORDING TO BMW, THIS ULTIMATELY COULD RESULT IN A LOCALIZED SMOLDERING CONDITION THAT DOES NOT PROPAGATE. TO CORRECT THE WATER INGRESS ISSUE, BMW IMPLEMENTED CHANGES TO THE WIRE ROUTING, THE POWER STEERINGPUMP CONNECTOR AND THE GROUND EYELET CONNECTION BETWEEN FEBRUARY AND JULY OF 2002. IN A REVIEW OF WARRANTY CLAIM DATA SENT BY BMW, 67 PERCENT OF THE VEHICLES NOTED IN WARRANTY CLAIMS HAD PRODUCTION DATES AFTER AUGUST 1, 2002. ADDITIONALLY, ODI NOTED EIGHT REPORTS OF CONSUMERS WITNESSING FLAMES COMING FROM THE ENGINE COMPARTMENT.THIS PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA07-011) TO FURTHER ASSESS THE SCOPE, FREQUENCY ANDPOTENTIAL SAFETY CONSEQUENCES ASSOCIATED WITH THE ALLEGED DEFECT.
Additional source detail variants (4)
Steering:electric Power Assist System
IN RESPONSE TO AN INFORMATION REQUEST (IR) LETTER SENT BY THE OFFICE OF DEFECTS INVESTIGATION (ODI), BMW STATED THAT THE CAUSE OF THE ALLEGED DEFECT IS AN INSUFFICIENT SEAL OF THE GROUND CABLE OF THE POWER STEERING PUMP AT ITS ATTACHMENT TO THE CHASSIS.WATER INGRESS CAN OCCUR AND THE WATER CAN TRAVEL ALONG THE POWER STEERING PUMP POWER CABLE AND COME IN CONTACT WITH THE POWER STEERING PUMP POWER CABLE CONNECTOR.THE CONNECTOR CAN THEN CORRODE AND A HIGH THERMAL LOAD CONDITION CAN OCCUR.ACCORDING TO BMW, THIS ULTIMATELY COULD RESULT IN A LOCALIZED SMOLDERING CONDITION THAT DOES NOT PROPAGATE. TO CORRECT THE WATER INGRESS ISSUE, BMW IMPLEMENTED CHANGES TO THE WIRE ROUTING, THE POWER STEERINGPUMP CONNECTOR AND THE GROUND EYELET CONNECTION BETWEEN FEBRUARY AND JULY OF 2002. IN A REVIEW OF WARRANTY CLAIM DATA SENT BY BMW, 67 PERCENT OF THE VEHICLES NOTED IN WARRANTY CLAIMS HAD PRODUCTION DATES AFTER AUGUST 1, 2002. ADDITIONALLY, ODI NOTED EIGHT REPORTS OF CONSUMERS WITNESSING FLAMES COMING FROM THE ENGINE COMPARTMENT.THIS PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA07-011) TO FURTHER ASSESS THE SCOPE, FREQUENCY ANDPOTENTIAL SAFETY CONSEQUENCES ASSOCIATED WITH THE ALLEGED DEFECT.
Steering:hydraulic Power Assist:hose, Piping, And Connections
IN RESPONSE TO AN INFORMATION REQUEST (IR) LETTER SENT BY THE OFFICE OF DEFECTS INVESTIGATION (ODI), BMW STATED THAT THE CAUSE OF THE ALLEGED DEFECT IS AN INSUFFICIENT SEAL OF THE GROUND CABLE OF THE POWER STEERING PUMP AT ITS ATTACHMENT TO THE CHASSIS.WATER INGRESS CAN OCCUR AND THE WATER CAN TRAVEL ALONG THE POWER STEERING PUMP POWER CABLE AND COME IN CONTACT WITH THE POWER STEERING PUMP POWER CABLE CONNECTOR.THE CONNECTOR CAN THEN CORRODE AND A HIGH THERMAL LOAD CONDITION CAN OCCUR.ACCORDING TO BMW, THIS ULTIMATELY COULD RESULT IN A LOCALIZED SMOLDERING CONDITION THAT DOES NOT PROPAGATE. TO CORRECT THE WATER INGRESS ISSUE, BMW IMPLEMENTED CHANGES TO THE WIRE ROUTING, THE POWER STEERINGPUMP CONNECTOR AND THE GROUND EYELET CONNECTION BETWEEN FEBRUARY AND JULY OF 2002. IN A REVIEW OF WARRANTY CLAIM DATA SENT BY BMW, 67 PERCENT OF THE VEHICLES NOTED IN WARRANTY CLAIMS HAD PRODUCTION DATES AFTER AUGUST 1, 2002. ADDITIONALLY, ODI NOTED EIGHT REPORTS OF CONSUMERS WITNESSING FLAMES COMING FROM THE ENGINE COMPARTMENT.THIS PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA07-011) TO FURTHER ASSESS THE SCOPE, FREQUENCY ANDPOTENTIAL SAFETY CONSEQUENCES ASSOCIATED WITH THE ALLEGED DEFECT.
Steering:hydraulic Power Assist:pump
IN RESPONSE TO AN INFORMATION REQUEST (IR) LETTER SENT BY THE OFFICE OF DEFECTS INVESTIGATION (ODI), BMW STATED THAT THE CAUSE OF THE ALLEGED DEFECT IS AN INSUFFICIENT SEAL OF THE GROUND CABLE OF THE POWER STEERING PUMP AT ITS ATTACHMENT TO THE CHASSIS.WATER INGRESS CAN OCCUR AND THE WATER CAN TRAVEL ALONG THE POWER STEERING PUMP POWER CABLE AND COME IN CONTACT WITH THE POWER STEERING PUMP POWER CABLE CONNECTOR.THE CONNECTOR CAN THEN CORRODE AND A HIGH THERMAL LOAD CONDITION CAN OCCUR.ACCORDING TO BMW, THIS ULTIMATELY COULD RESULT IN A LOCALIZED SMOLDERING CONDITION THAT DOES NOT PROPAGATE. TO CORRECT THE WATER INGRESS ISSUE, BMW IMPLEMENTED CHANGES TO THE WIRE ROUTING, THE POWER STEERINGPUMP CONNECTOR AND THE GROUND EYELET CONNECTION BETWEEN FEBRUARY AND JULY OF 2002. IN A REVIEW OF WARRANTY CLAIM DATA SENT BY BMW, 67 PERCENT OF THE VEHICLES NOTED IN WARRANTY CLAIMS HAD PRODUCTION DATES AFTER AUGUST 1, 2002. ADDITIONALLY, ODI NOTED EIGHT REPORTS OF CONSUMERS WITNESSING FLAMES COMING FROM THE ENGINE COMPARTMENT.THIS PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA07-011) TO FURTHER ASSESS THE SCOPE, FREQUENCY ANDPOTENTIAL SAFETY CONSEQUENCES ASSOCIATED WITH THE ALLEGED DEFECT.
Steering:hydraulic Power Assist System
IN RESPONSE TO AN INFORMATION REQUEST (IR) LETTER SENT BY THE OFFICE OF DEFECTS INVESTIGATION (ODI), BMW STATED THAT THE CAUSE OF THE ALLEGED DEFECT IS AN INSUFFICIENT SEAL OF THE GROUND CABLE OF THE POWER STEERING PUMP AT ITS ATTACHMENT TO THE CHASSIS.WATER INGRESS CAN OCCUR AND THE WATER CAN TRAVEL ALONG THE POWER STEERING PUMP POWER CABLE AND COME IN CONTACT WITH THE POWER STEERING PUMP POWER CABLE CONNECTOR.THE CONNECTOR CAN THEN CORRODE AND A HIGH THERMAL LOAD CONDITION CAN OCCUR.ACCORDING TO BMW, THIS ULTIMATELY COULD RESULT IN A LOCALIZED SMOLDERING CONDITION THAT DOES NOT PROPAGATE. TO CORRECT THE WATER INGRESS ISSUE, BMW IMPLEMENTED CHANGES TO THE WIRE ROUTING, THE POWER STEERINGPUMP CONNECTOR AND THE GROUND EYELET CONNECTION BETWEEN FEBRUARY AND JULY OF 2002. IN A REVIEW OF WARRANTY CLAIM DATA SENT BY BMW, 67 PERCENT OF THE VEHICLES NOTED IN WARRANTY CLAIMS HAD PRODUCTION DATES AFTER AUGUST 1, 2002. ADDITIONALLY, ODI NOTED EIGHT REPORTS OF CONSUMERS WITNESSING FLAMES COMING FROM THE ENGINE COMPARTMENT.THIS PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA07-011) TO FURTHER ASSESS THE SCOPE, FREQUENCY ANDPOTENTIAL SAFETY CONSEQUENCES ASSOCIATED WITH THE ALLEGED DEFECT.
PE05053 · Air Bag Warning Lamp Illumination
Opened Sep 27, 2005 · Closed Mar 1, 2006
Status: closed (inferred from source dates) · Air Bags; Air Bags:side/window
IN MARCH 2006, BMW REISSUED A SERVICE BULLETIN FIRST ISSUED IN SEPTEMBER 2003, TO MINI DEALERS REGARDING THE REPAIR PROCEDURE FOR IMPROPER WIRE CRIMPS IN APPROXIMATELY 31,500 MODEL YEAR 2002 AND 2003 MINI COOPER VEHICLES PRODUCED UP TO JANUARY 2003.THE NEW SERVICE BULLETIN STATES THAT THE WARRANTY COVERAGE FOR THE ISSUE (I.E., AIR BAG WARNING LAMP ILLUMINATION WITH FAULT CODE FOR HIGH RESISTANCE IN SIDE AIR BAG/SEAT BELT PRETENSIONER CIRCUIT) IS EXTENDED TO 10 YEARS OR 150,000 MILES, WHICHEVER OCCURS FIRST.BMW PLANS TO SEND LETTERS TO OWNERS DURING MARCH 2006.THE SUBJECT WIRE CRIMPS ARE LOCATED UNDER THE FRONT SEATS AND ARE PART OF THE MAIN WIRING HARNESS THAT INTERFACE WITH THE UNDER-SEAT WIRING HARNESS CONNECTORS FOR SIDE AIR BAG AND SEAT BELT PRETENSIONER MODULES.BMW STATED THAT, ALTHOUGH THE SUBJECT CRIMPS WERE IMPROPERLY MANUFACTURED, THE CRIMP CONNECTION IS STILL SUFFICIENT FOR THE RESTRAINT SYSTEM TO DEPLOY WHEN NEEDED.ACCORDING TO BMW, THE ELECTRICAL RESISTANCE LEVELS IN THE SUBJECT VEHICLES CAN EXCEED THE THRESHOLD THAT ILLUMINATES THE AIR BAG WARNING LAMP, BUT THEY DO NOT EXCEED A MUCH HIGHER LIMIT IN WHICH DEPLOYMENT OF THE RESTRAINTS MAY NO LONGER OCCUR.ODI BELIEVES THAT THERE IS LACK OF EVIDENCE AT THIS TIME TO CONCLUDE THAT THE RESTRAINT SYSTEMS MAY NOT DEPLOY WITH THE HIGH RESISTANCE CONDITION.THE AGENCY BELIEVES THAT FURTHER EXPENDITURE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED AT THIS TIME.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS.THE AGENCY WILL MONITOR THE ISSUE AND RESERVES THE RIGHT TO TAKE FUTURE ACTION IF WARRANTED BY THE CIRCUMSTANCES.
Additional source detail variants (2)
Air Bags
IN MARCH 2006, BMW REISSUED A SERVICE BULLETIN FIRST ISSUED IN SEPTEMBER 2003, TO MINI DEALERS REGARDING THE REPAIR PROCEDURE FOR IMPROPER WIRE CRIMPS IN APPROXIMATELY 31,500 MODEL YEAR 2002 AND 2003 MINI COOPER VEHICLES PRODUCED UP TO JANUARY 2003.THE NEW SERVICE BULLETIN STATES THAT THE WARRANTY COVERAGE FOR THE ISSUE (I.E., AIR BAG WARNING LAMP ILLUMINATION WITH FAULT CODE FOR HIGH RESISTANCE IN SIDE AIR BAG/SEAT BELT PRETENSIONER CIRCUIT) IS EXTENDED TO 10 YEARS OR 150,000 MILES, WHICHEVER OCCURS FIRST.BMW PLANS TO SEND LETTERS TO OWNERS DURING MARCH 2006.THE SUBJECT WIRE CRIMPS ARE LOCATED UNDER THE FRONT SEATS AND ARE PART OF THE MAIN WIRING HARNESS THAT INTERFACE WITH THE UNDER-SEAT WIRING HARNESS CONNECTORS FOR SIDE AIR BAG AND SEAT BELT PRETENSIONER MODULES.BMW STATED THAT, ALTHOUGH THE SUBJECT CRIMPS WERE IMPROPERLY MANUFACTURED, THE CRIMP CONNECTION IS STILL SUFFICIENT FOR THE RESTRAINT SYSTEM TO DEPLOY WHEN NEEDED.ACCORDING TO BMW, THE ELECTRICAL RESISTANCE LEVELS IN THE SUBJECT VEHICLES CAN EXCEED THE THRESHOLD THAT ILLUMINATES THE AIR BAG WARNING LAMP, BUT THEY DO NOT EXCEED A MUCH HIGHER LIMIT IN WHICH DEPLOYMENT OF THE RESTRAINTS MAY NO LONGER OCCUR.ODI BELIEVES THAT THERE IS LACK OF EVIDENCE AT THIS TIME TO CONCLUDE THAT THE RESTRAINT SYSTEMS MAY NOT DEPLOY WITH THE HIGH RESISTANCE CONDITION.THE AGENCY BELIEVES THAT FURTHER EXPENDITURE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED AT THIS TIME.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS.THE AGENCY WILL MONITOR THE ISSUE AND RESERVES THE RIGHT TO TAKE FUTURE ACTION IF WARRANTED BY THE CIRCUMSTANCES.
Air Bags:side/window
IN MARCH 2006, BMW REISSUED A SERVICE BULLETIN FIRST ISSUED IN SEPTEMBER 2003, TO MINI DEALERS REGARDING THE REPAIR PROCEDURE FOR IMPROPER WIRE CRIMPS IN APPROXIMATELY 31,500 MODEL YEAR 2002 AND 2003 MINI COOPER VEHICLES PRODUCED UP TO JANUARY 2003.THE NEW SERVICE BULLETIN STATES THAT THE WARRANTY COVERAGE FOR THE ISSUE (I.E., AIR BAG WARNING LAMP ILLUMINATION WITH FAULT CODE FOR HIGH RESISTANCE IN SIDE AIR BAG/SEAT BELT PRETENSIONER CIRCUIT) IS EXTENDED TO 10 YEARS OR 150,000 MILES, WHICHEVER OCCURS FIRST.BMW PLANS TO SEND LETTERS TO OWNERS DURING MARCH 2006.THE SUBJECT WIRE CRIMPS ARE LOCATED UNDER THE FRONT SEATS AND ARE PART OF THE MAIN WIRING HARNESS THAT INTERFACE WITH THE UNDER-SEAT WIRING HARNESS CONNECTORS FOR SIDE AIR BAG AND SEAT BELT PRETENSIONER MODULES.BMW STATED THAT, ALTHOUGH THE SUBJECT CRIMPS WERE IMPROPERLY MANUFACTURED, THE CRIMP CONNECTION IS STILL SUFFICIENT FOR THE RESTRAINT SYSTEM TO DEPLOY WHEN NEEDED.ACCORDING TO BMW, THE ELECTRICAL RESISTANCE LEVELS IN THE SUBJECT VEHICLES CAN EXCEED THE THRESHOLD THAT ILLUMINATES THE AIR BAG WARNING LAMP, BUT THEY DO NOT EXCEED A MUCH HIGHER LIMIT IN WHICH DEPLOYMENT OF THE RESTRAINTS MAY NO LONGER OCCUR.ODI BELIEVES THAT THERE IS LACK OF EVIDENCE AT THIS TIME TO CONCLUDE THAT THE RESTRAINT SYSTEMS MAY NOT DEPLOY WITH THE HIGH RESISTANCE CONDITION.THE AGENCY BELIEVES THAT FURTHER EXPENDITURE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED AT THIS TIME.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS.THE AGENCY WILL MONITOR THE ISSUE AND RESERVES THE RIGHT TO TAKE FUTURE ACTION IF WARRANTED BY THE CIRCUMSTANCES.
DP05006 · Air Bag Warning Lamp Illumination
Opened Sep 19, 2005 · Closed Oct 6, 2005
Status: closed (inferred from source dates) · Air Bags; Air Bags:side/window
ODI HAS GRANTED THE PETITION AND HAS OPENED A PRELIMINARY EVALUATION (PE05-053) ON ILLUMINATION OF AIR BAG WARNING LAMP ON MODEL YEAR 2002 AND 2003 MINI COOPER VEHICLES.
Additional source detail variants (2)
Air Bags
ODI HAS GRANTED THE PETITION AND HAS OPENED A PRELIMINARY EVALUATION (PE05-053) ON ILLUMINATION OF AIR BAG WARNING LAMP ON MODEL YEAR 2002 AND 2003 MINI COOPER VEHICLES.
Air Bags:side/window
ODI HAS GRANTED THE PETITION AND HAS OPENED A PRELIMINARY EVALUATION (PE05-053) ON ILLUMINATION OF AIR BAG WARNING LAMP ON MODEL YEAR 2002 AND 2003 MINI COOPER VEHICLES.