IllustrationPOWER STEERING FAILED MAKING IT DIFFICULT TO DRIVE/ TURN VEHICLE. THIS HAS HAPPENED MULTIPLE TIMES. TYPICALLY THE POWER STEERING COMES BACK AFTER A MINUTE OR TWO BUT DURING THE LATEST INCIDENT IT DID NOT COME BACK ON. *TR
2004 Mini Cooper
Owner reports · Recalls · Investigations
More warning signs than most Cooper years
Owner complaints for the 2004 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
130–25K
3325–50K
8750–75K
6375–100K
49100–150K
9150K+
254 reports with mileage · 28 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 238 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Power Train. Review the 26 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Electrical System. Review the 15 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
5 crash reports9 fire reports1 injury reports
What owners actually said
282 reportsPOWER STEERING FAILED WHILE ON A HIGHWAY. *TR
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
LENT CAR TO BOYFRIEND TO DRIVE ME TO BOSTON (100 MILE ONE WAY). ON THE WAY HOME HE STOPPED AT A STORE APPROXIMATELY 10 MILES FROM THE HOUSE. WHEN HE CAME BACK OUT OF THE STORE ( WAS IN STORE APPROXIMATELY 10 MINUTES) THE POWER STEERING NO LONGER WORKED. IT WAS LIKE TRYING TO STEER THROUGH CONCRETE FOR HIM. A FEW DAYS LATER H…
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LENT CAR TO BOYFRIEND TO DRIVE ME TO BOSTON (100 MILE ONE WAY). ON THE WAY HOME HE STOPPED AT A STORE APPROXIMATELY 10 MILES FROM THE HOUSE. WHEN HE CAME BACK OUT OF THE STORE ( WAS IN STORE APPROXIMATELY 10 MINUTES) THE POWER STEERING NO LONGER WORKED. IT WAS LIKE TRYING TO STEER THROUGH CONCRETE FOR HIM. A FEW DAYS LATER HE TRIED THE CAR AND IT ALL WORKED FINE AGAIN. BASED ON PRIOR COMPLAINTS FILED, I AM CONCERNED THAT THE ISSUE WILL REOCCUR WHEN I AM DRIVING CAUSING OBVIOUS SAFETY CONCERNS, OR THAT IT MAY CATCH FIRE (BASED ON OTHER COMPLAINTS FILED FOR SIMILAR ISSUES) AND THAT I WILL BE FACING THE COST OF REPLACING THE POWER STEERING UNIT (WHICH DOES NOT SOUND LIKE IT HAS BEEN REENGINEERED SINCE THIS ISSUE BECAME KNOWN).
POWER STEERING FROZE UP AS WE TURNED A CORNER AND THEN DIED OUT COMPLETELY. IT HAS NEVER RETURNED. VERY CLOSE TO CAUSING A COLLISION BECAUSE OF THE LOSS OF POWER STEERING. *TR
WHILE DRIVING THE POWER STEERING CUT OUT CREATING AN UNSAFE DRIVING CONDITION. OVER THE NEXT 20,000 MILES THE POWER STEERING WOULD INTERMITTENTLY COME BACK AND GO OUT MORE THAN A DOZEN TIMES UNTIL EVENTUALLY FAILING COMPLETELY. *TR
THE CARS POWER STEERING STARTED FAILING FOR A FEW SECONDS WHILE DRIVING AT SLOW SPEED. THIS HAS HAPPENED AT LEAST 20 OR MORE TIMES OVER THE LAST 2 YEARS. THE STEERING OF THE VEHICLE BECOMES EXTREMELY HARD. THERE IS NO WARNING THAT THIS WILL OCCUR, SO CLEARLY IT COULD RESULT IN AN ACCIDENT. IN THE LAST 12 MONTHS, THE POWER ST…
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THE CARS POWER STEERING STARTED FAILING FOR A FEW SECONDS WHILE DRIVING AT SLOW SPEED. THIS HAS HAPPENED AT LEAST 20 OR MORE TIMES OVER THE LAST 2 YEARS. THE STEERING OF THE VEHICLE BECOMES EXTREMELY HARD. THERE IS NO WARNING THAT THIS WILL OCCUR, SO CLEARLY IT COULD RESULT IN AN ACCIDENT. IN THE LAST 12 MONTHS, THE POWER STEERING HAS STARTED TO FAIL WHEN THE CAR IS STARTED, BUT STARTED WORKING AGAIN IF THE CAR WAS RESTARTED OR AFTER A SHORT PERIOD OF TIME. THIS WEEK, AFTER 3 HOURS OF DRIVING, THE CAR WAS PARKED FOR 15 MINUTES, WHEN THE CAR WAS RESTARTED THERE WAS NO POWER STEERING AT ALL DURING ANOTHER 5 MINUTES OF DRIVING. THE CARE WAS STOPPED FOR ANOTHER 20 MINUTES AND WHEN RESTARTED POWER STEERING WAS RESTORED. I AM VERY CONCERNED THAT THIS FAILURE COULD OCCUR DURING HIGH SPEED MANEUVERING AND COULD RESULT IN A MAJOR ACCIDENT. I FEEL THAT I HAVE BEEN LUCKY TO DATE THAT I HAVEN'T BEEN IN A SITUATION THAT RESULTED IN AN ACCIDENT, PRECISE CONTROL OF THE VEHICLE IS IMPOSSIBLE WITHOUT THE POWER STEERING. *TR
TL* THE CONTACT OWNS A 2004 MINI COOPER. THE CONTACT STATED THAT THE POWER STEERING ASSIST FAILED WITHOUT WARNING, CAUSING EXTREME DIFFICULTY IN STEERING CONTROL. THE VEHICLE WAS NOT TAKEN TO THE DEALER FOR DIAGNOSTIC TESTING OR REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE VIN WAS NOT AVAILABLE. THE FAILURE AND…
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TL* THE CONTACT OWNS A 2004 MINI COOPER. THE CONTACT STATED THAT THE POWER STEERING ASSIST FAILED WITHOUT WARNING, CAUSING EXTREME DIFFICULTY IN STEERING CONTROL. THE VEHICLE WAS NOT TAKEN TO THE DEALER FOR DIAGNOSTIC TESTING OR REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE VIN WAS NOT AVAILABLE. THE FAILURE AND THE CURRENT MILEAGE WAS 120,000.
STEERING FLUID PUMP WAS JUST REPLACED A FEW WEEKS AGO, PROBLEM HAS RETURNED AND WILL NOT GO AWAY... STEERING WHEEL VERY RIGID HARD TO TURN. VERY DIFFICULT TO MAKE TURNS, ALOT OF EFFORT TO TURN THE STEERING WHEEL. TRYING TO MAKE A SHARP OR QUICK TURN IF NEEDED, WOULD BE DANGEROUS & ALMOST IMPOSSIBLE. I RECENTLY RESEARCHED AND F…
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STEERING FLUID PUMP WAS JUST REPLACED A FEW WEEKS AGO, PROBLEM HAS RETURNED AND WILL NOT GO AWAY... STEERING WHEEL VERY RIGID HARD TO TURN. VERY DIFFICULT TO MAKE TURNS, ALOT OF EFFORT TO TURN THE STEERING WHEEL. TRYING TO MAKE A SHARP OR QUICK TURN IF NEEDED, WOULD BE DANGEROUS & ALMOST IMPOSSIBLE. I RECENTLY RESEARCHED AND FOUND THAT THOUSANDS OF 04 MINI COOPERS HAD THIS SAME PROBLEM. *TR
POWER ASSISTED STEERING WILL CEASE WORKING WHILE DRIVING, MAKING THE CAR VERY, VERY DIFFICULT TO STEER/CONTROL. THIS PROBLEM IS CURRENTLY INTERMITTENT, BUT WHEN IT DOES HAPPEN IT IS VERY SCARY. CURRENTLY, I WILL NOT ALLOW MY WIFE OR GRANDCHILDREN IN THE CAR UNTIL I FIX THIS PROBLEM. MINI USA THRU MAIN LINE MINI, BALA CYNWYD, …
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POWER ASSISTED STEERING WILL CEASE WORKING WHILE DRIVING, MAKING THE CAR VERY, VERY DIFFICULT TO STEER/CONTROL. THIS PROBLEM IS CURRENTLY INTERMITTENT, BUT WHEN IT DOES HAPPEN IT IS VERY SCARY. CURRENTLY, I WILL NOT ALLOW MY WIFE OR GRANDCHILDREN IN THE CAR UNTIL I FIX THIS PROBLEM. MINI USA THRU MAIN LINE MINI, BALA CYNWYD, PA STATED NO RECALL FOR THIS VEHICLE VIA EMAIL. RESEARCH OF NHTSA ONLINE DATA BASE SHOWS 113 REPORTED COMPLAINTS FOR YEAR 2004 MINI'S AND 120 FOR YEAR 2005 FOR STEERING PROBLEMS AND NO FIX BY BMW. THIS IS A SERIOUS SAFETY PROBLEM AND SUGGEST READERS FILE COMPLAINTS AND HOPE IT DOES NOT TAKE A DEATH TO GET SOMEONE'S ATTENTION. *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).