NHTSA owner reports · September 18, 2026 snapshot.
Electrical System complaints
15 reportsClear category filter130,000 miles · Aug 16, 2016
Electrical System
TL* THE CONTACT OWNS A 2004 MINI COOPER. THE CONTACT STATED THAT THE VEHICLE'S BATTERY WAS LOCATED IN FRONT OF THE FIREWALL ABOVE THE GEAR BOX. THE BATTERY ACID LEAKED ONTO TWO SHIFTER CABLE LINKAGES, WHICH CAUSED THEM TO MELT UNEXPECTEDLY. THE VEHICLE WOULD NOT SHIFT GEARS. THE CONTACT ALSO STATED THAT THE SAME FAILURE OCCURRED…
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TL* THE CONTACT OWNS A 2004 MINI COOPER. THE CONTACT STATED THAT THE VEHICLE'S BATTERY WAS LOCATED IN FRONT OF THE FIREWALL ABOVE THE GEAR BOX. THE BATTERY ACID LEAKED ONTO TWO SHIFTER CABLE LINKAGES, WHICH CAUSED THEM TO MELT UNEXPECTEDLY. THE VEHICLE WOULD NOT SHIFT GEARS. THE CONTACT ALSO STATED THAT THE SAME FAILURE OCCURRED ONE OTHER TIME. THE VEHICLE WAS REPAIRED SIX MONTHS AGO BECAUSE OF THE SAME FAILURE. THE MANUFACTURER WAS NOTIFIED. THE VEHICLE WAS NOT REPAIRED AGAIN. THE APPROXIMATE FAILURE MILEAGE WAS 130,000.
NHTSA ODI #10896248
135,000 miles · Jun 17, 2016
Electrical SystemService BrakesStructureFire
DRIVING DOWN HONDA PARKWAY I HEARD POP SOUND. TPMS LIGHT STARTED FLASHING AND SMOKE STARTED COMING OUT FROM UNDER HOOD. I PULLED OFF OF ROAD INTO A GAS STATION. AT THAT TIME I DIDN'T HAVE ANY POWER BRAKES.THE CAR WAS FULLY ENGULFED IN FLAMES IN ABOUT 10 MINS. THE FIRE DEPT PUT OUT FIRE.
NHTSA ODI #10874841
90,000 miles · May 1, 2013
Electrical SystemSteering
I DROVE MY SISTER'S 2004 MINI COOPER SOMETIME IN SPRING OF 2012 TO CHECK ON WORK DONE FROM THE DEALERSHIP. AS I YIELDED INTO A ROUNDABOUT AND ENTERED IT, THE POWER STEERING CUT OFF WHICH STEERING EFFORT BECAME VERY HEAVY AND VERY NEARLY HAD A COLLISION WITH ANOTHER VEHICLE. I SISTER INFORMED ME AFTERWARDS THAT THE ISSUE JUST H…
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I DROVE MY SISTER'S 2004 MINI COOPER SOMETIME IN SPRING OF 2012 TO CHECK ON WORK DONE FROM THE DEALERSHIP. AS I YIELDED INTO A ROUNDABOUT AND ENTERED IT, THE POWER STEERING CUT OFF WHICH STEERING EFFORT BECAME VERY HEAVY AND VERY NEARLY HAD A COLLISION WITH ANOTHER VEHICLE. I SISTER INFORMED ME AFTERWARDS THAT THE ISSUE JUST HAPPEN RECENTLY OCCURRED TO HER TOO, AS SHE EXITED A HIGHWAY EXIT RAMP AT NEARLY 55MPH, AND POWER STEERING HAD FAILED. LUCKILY, SHE WAS ABLE TO REACT QUICKLY WITH THE POWER STEERING LOSS. PULLED TO THE SIDE, SHUT THE VEHICLE, AND TURNED ON THE VEHICLE AGAIN, AND POWER STEERING CAME BACK ON. IT HAS INTERMITTENTLY GOING OFF/ON W POWER SINCE THEN WHICH THE DEALER RECOGNIZES, BUT WARRANTY HAS BEEN EXPIRED SINCE IT'S 9 YEARS AND OVER 100,000 MI. AND WE ARE LEFT WITH A BILL AT AROUND $1,400 AVERAGE. $800 IN PARTS ALONE. THERE ARE MANY MINI CUSTOMERS KNOWN TO HAVE THIS ISSUE OF POWER STEERING LOSS IN THEIR EARLY MODELS TOO, SAME AS MY SISTER'S YEAR MODEL. SO FAR FORTUNATELY, THERE ARE NO INJURIES NOR FATALITIES DIRECTLY FROM THIS POWER STEERING LOSS FROM WHAT I KNOW OF. BUT MANY ARE FACED WITH THIS LARGE REPAIR WITH WE'RE FACING, AND SOME MAY FOREGO/ DELAY REPAIRING IT. TRANSPORT CANADA, RECOGNIZES THIS AS A SAFETY ISSUE, AND RECALLED ABOUT 9,000 MINI'S LAST YEAR. AND THE POWER STEERING PUMP PART IS NO DIFFERENT THAN THEIRS. WHEN ARE WE GOING TO ACT LIKE OUR NEIGHBORS? UNTIL WE GET SOMEONE HORRIBLY INJURED OR KILLED?! OR HAVE MINI CUSTOMERS SUCH MY SISTER FACING THIS LARGE REPAIR ORDER ON THIS DEFECTIVE PART THAT'S KNOWN TO FAIL PREMATURELY? THIS IS A SERIOUS GAMBLE WITH LIVES. *TR
NHTSA ODI #10510202
55,000 miles · Feb 12, 2013
Electrical SystemExterior LightingSteering
DRIVING OFF-RAMP AT 35 MPH POWER STEERING STOPPED FUNCTIONING AND STEERING BECAME REALLY HARD, LIGHTS WENT OFF, AC STOPPED WORKING, AND LOTS OF ENGINE LIGHTS CAME UP, ALMOST CRASHED WHEN TURNING A CORNER AND ENGINE STARTED FAILING.....GOT HOME AND SHUT OFF CAR, WHEN TRIED TO TURN ON AGAIN, IT FAILED TO START....... *TR
NHTSA ODI #10497950
38,000 miles · Oct 20, 2012
Electrical SystemSteering
12-4-10: THE POWER STEERING PUMP KEPT RUNNING AFTER THE CAR WAS OFF AND DRAINED THE BATTERY IN 2 HOURS. SEPT., 2012: TWO INCIDENTS OF POWER STEERING LOSS WHILE DRIVING. FIRST TIME I HAD NO POWER STEERING WHEN I STARTED THE CAR. I DROVE A SHORT DISTANCE, STOPPED AND RESTARTED THE CAR AND THE POWER STEERING WORKED. SECOND TIME I L…
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12-4-10: THE POWER STEERING PUMP KEPT RUNNING AFTER THE CAR WAS OFF AND DRAINED THE BATTERY IN 2 HOURS. SEPT., 2012: TWO INCIDENTS OF POWER STEERING LOSS WHILE DRIVING. FIRST TIME I HAD NO POWER STEERING WHEN I STARTED THE CAR. I DROVE A SHORT DISTANCE, STOPPED AND RESTARTED THE CAR AND THE POWER STEERING WORKED. SECOND TIME I LOST POWER STEERING BRIEFLY WHILE DRIVING AT LOW SPEED. MY MECHANIC FOUND THAT THE POWER STEERING FAN HAD SEIZED AND REPLACED IT. WHEN HE TOOK IT FOR A TEST DRIVE, THE POWER STEERING PUMP WAS MAKING A LOUD NOISE. HE REPLACED THE PUMP AS WELL AND THE PROBLEMS WERE CORRECTED. *TR
NHTSA ODI #10481261
140,000 miles · Aug 27, 2012
Electrical SystemSteeringVehicle Speed Control
THE POWER STEERING FAILED, COMMON PROBLEM IN 2004 MINI COOPER. CANADA HAS ISSUED A RECALL IN JANUARY 2012. *TR
NHTSA ODI #10472537
83,000 miles · Jun 22, 2012
Electrical SystemSteering
THE VEHICLE HAD BEEN ACTING STRANGE FOR THE LAST COUPLE OF MONTHS, THE STEERING WOULD BECOME HEAVY AT TIMES, AND ON THE OTHER OCCASIONS WOULD WORK JUST FINE. A TRIP TO THE DEALERSHIP REVEALED THAT THE POWER STEERING PUMP HAD FAILED. THIS SEEMS LIKE A KNOWN ISSUE WITH MOST OF THE 2004 MINI COOPERS, A DEFECTIVE PART WAS PUT INTO T…
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THE VEHICLE HAD BEEN ACTING STRANGE FOR THE LAST COUPLE OF MONTHS, THE STEERING WOULD BECOME HEAVY AT TIMES, AND ON THE OTHER OCCASIONS WOULD WORK JUST FINE. A TRIP TO THE DEALERSHIP REVEALED THAT THE POWER STEERING PUMP HAD FAILED. THIS SEEMS LIKE A KNOWN ISSUE WITH MOST OF THE 2004 MINI COOPERS, A DEFECTIVE PART WAS PUT INTO THE CAR WHILE MANUFACTING. MINI IS NOT TAKING ANY RESPONSIBILITY OF IT, AND THE DEALERSHIP IS ASKING FOR $1200 TO REPLACE IT. DUE TO THE POWER PUMP FAILURE, THE TEMPARATURE RISES AND MAY HAVE CAUSED DAMAGE TO A FEW HOSES AROUND THAT AREA. *TT
NHTSA ODI #10462686
50,144 miles · May 23, 2012
Electrical SystemSteeringFire
LOST POWER STEERING AT HIGHWAY SPEED DUE TO POWER STEERING PUMP FAILURE. SHORT CIRCUIT OR FIRE MELTED POWER STEERING PUMP WIRING HARNESS. DAMAGE WAS CAUSED TO OTHER PORTIONS OF ELECTRICAL WIRING HARNESS BY FIRE, RESULTING IN BLOWN FUSES. UPON REMOVING KEY FROM IGNITION AT ROADSIDE, ENGINE KEPT RUNNING UNTIL BATTERY WAS DISCONNEC…
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LOST POWER STEERING AT HIGHWAY SPEED DUE TO POWER STEERING PUMP FAILURE. SHORT CIRCUIT OR FIRE MELTED POWER STEERING PUMP WIRING HARNESS. DAMAGE WAS CAUSED TO OTHER PORTIONS OF ELECTRICAL WIRING HARNESS BY FIRE, RESULTING IN BLOWN FUSES. UPON REMOVING KEY FROM IGNITION AT ROADSIDE, ENGINE KEPT RUNNING UNTIL BATTERY WAS DISCONNECTED. *TT
NHTSA ODI #10459378
30,000 miles · Jan 21, 2012
Electrical SystemElectronic Stability Control (esc)Power TrainFire
VERY DISAPPOINTED WITH MINI COOPER AND THE CORPORATION OF BMW ON HOW THEY HANDLED MY ISSUES WITH MY 2004 MINI. I CAME TO THE DEALERSHIP SEVERAL TIMES IN RAMSEY, NEW JERSEY WITH THE REPAIRS THAT WERE RECALLED. I HAD PRINTED THE RECALLS AS EVIDENCE THAT THERE WERE IDENTICAL ISSUES AS THE REPAIRS NEEDED TO MY CAR! THE DEALERSHIP…
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VERY DISAPPOINTED WITH MINI COOPER AND THE CORPORATION OF BMW ON HOW THEY HANDLED MY ISSUES WITH MY 2004 MINI. I CAME TO THE DEALERSHIP SEVERAL TIMES IN RAMSEY, NEW JERSEY WITH THE REPAIRS THAT WERE RECALLED. I HAD PRINTED THE RECALLS AS EVIDENCE THAT THERE WERE IDENTICAL ISSUES AS THE REPAIRS NEEDED TO MY CAR! THE DEALERSHIP IGNORED AND REFUSED TO EVEN LOOK AT THE RECALLS ON PAPER AND TO MY DISMAY I WAS FORCED TO PAY OUT-OF-MY-OWN POCKET! I HAD NO CHOICE BECAUSE OF MY CONCERN TO DRIVE A 'SAFE' VEHICLE. TO MY DISAPPOINTMENT I HAD TO RETURN BACK TO THE DEALERSHIP WITH THE SAME AND ADDITIONAL ISSUES THAT WERE NO REPAIRED! THE NEXT DAY THE MANAGER ASSURED ME THAT ALL WAS TAKEN CARE OF AND THE CAR WAS FINALLY SAFE! WRONG AGAIN! WITH ADDITIONAL CALLS TO BOTH THE DEALERSHIP AND BMW I STILL DID NOT HAVE A SOLUTION NOR A SAFE CAR! . THE ISSUES WERE: 1.BRAKE LIGHT BEING REPLACED MULTIPLE TIMES AND THEN CAUSED A FIRE. 2.STEERING 3.STABILITY CONTROL ULTIMATELY, I HAVE CONTACTED NHTSA SEVERAL TIMES TO ASSIST AND THE RESPONSE WAS TO CONTACT THE DEALER. I'M AT THE POINT I NEED TO NOW TAKE THIS TO A NEW LEVEL TO RESOLVE THIS SITUATION. *TR
NHTSA ODI #10444751
Mileage unknown · Nov 30, 2011
Electrical SystemSteeringFire
WHILE DRIVING IN A 35MPH ZONE, SMOKE STARTED COMING OUT FROM UNDER THE HOOD (BONNET). DRIVER NOTICED ODD STEERING RESPONSE SHORTLY BEFORE SMOKE APPEARED. REPAIR SHOP NOTED POWER STEERING PUMP FAILURE CAUSING WIRING LOOM FIRE. RESEARCH HAS FOUND NUMEROUS POWER STEERING PUMP FAILURES ON MINI COOPERS. WHEN POWER STEERING FAILS, DRI…
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WHILE DRIVING IN A 35MPH ZONE, SMOKE STARTED COMING OUT FROM UNDER THE HOOD (BONNET). DRIVER NOTICED ODD STEERING RESPONSE SHORTLY BEFORE SMOKE APPEARED. REPAIR SHOP NOTED POWER STEERING PUMP FAILURE CAUSING WIRING LOOM FIRE. RESEARCH HAS FOUND NUMEROUS POWER STEERING PUMP FAILURES ON MINI COOPERS. WHEN POWER STEERING FAILS, DRIVING IS NEXT TO IMPOSSIBLE GIVEN SIZE OF STEERING WHEEL AND POWER ASSIST DESIGN. *KB
NHTSA ODI #10437817
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).
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