2007 Mini Cooper

What happened: Vehicle has experienced failure of the Footwell Control Module (FRM) and associated wiring harness in the driver footwell area, consistent with NHTSA Recall 23V-337. Symptoms: • Exterior lights (headlights / taillights) remain illuminated far longer than normal after vehicle shutoff, sometimes not turning off at all. • Inspection revealed melted wiring, melted connector plugs and receptacles for headlight/taillight circuits. • Water was found in driver side footwell in the past / under carpet padding. Carpet pad is saturated. This is the same failure mode described in Recall 23V-337: "Due to a number of contributing factors, over time, the FRM could become susceptible to corrosion. Eventually, the corrosion could potentially result in a short circuit, resulting in a potential thermal event which could increase the risk of a fire or injury." Safety risk: Melted wiring and connectors create short circuit and thermal event risk, including fire risk while vehicle is parked and unattended. Lights failing to shut off creates dead battery / loss of exterior lighting control. I am concerned about vehicle fire. My vehicle shows evidence of having caught fire at the headlight and receptacle point. Recall history: Vehicle is included in NHTSA Campaign 23V-337000 (MINI Recall 23V-337 - Footwell Module Moisture/Water Intrusion). I was told remedy is still being developed / parts unavailable, or that additional wiring harness damage beyond the FRM itself is not fully covered. Dealer has inspected the vehicle and has completely disregarded the recall, which was the reason why I brought it in and have quoted me customer pay estimates for repairs covered under the recall. I am filing this to document that Recall 23V-337 failure has resulted in melted wiring harness components beyond just the FRM module, and to request NHTSA evaluate whether the current recall remedy fully addresses wiring harness damage caused by prolonged FRM corrosion / lights staying on.

The vehicle has been presenting issues with breaks, electrical issues, turning off while driving, misfires, air bags don't work, ADAS sometimes don't work, the vehicle chokes and has difficulty running at times, among other issues. There has been a recall since last year and I've tried contacting the manufacturer multiple times, but the issue has not been fixed yet. All of these problems are a great safety hazard for me and my family while on the road.

MY FUEL RAIL WAS SIPPING WITH GASOLINE. WHEN I BROUGHT MY CAR TO A MINI DEALER, THEY CLAIMED THAT IT WAS A WEAR AND TEAR PROBLEM AND REFUSED TO ACKNOWLEDGED THAT IT WAS A DESIGN FLAW. THE FUEL RAIL WAS PLASTIC AND THE LEAK WAS AT THE SEAL BETWEEN THE PLASTIC PARTS. IF THE FUEL RAIL IS METAL AND IS SOLDERED, THIS PROBLEM WOULD NOT HAVE HAPPENED. HAVING A FUEL RAIL THAT LEAKS COULD SEVERELY DAMAGE THE ENGINE AND CAUSE A FIRE. *TR