IllustrationWAS DRIVING MY SON HOME FROM A SOCCER TOURNAMENT, TRAVELING ABOUT 70 MPH, WHEN THE STEERING FAILED-I COULD ONLY TURN THE STEERING WHEEL ABOUT 1" IN EACH DIRECTION. TERRIFYING. THE PROBLEM PERSISTS, AND THE CAR IS UNSAFE TO DRIVE-I'LL PROBABLY NEED TO TOW IT TO THE MECHANIC. *TR
2004 Mini Cooper S
Owner reports · Recalls · Investigations
More warning signs than most Cooper S years
Owner complaints for the 2004 Mini Cooper S are substantially higher than the model-year median of 23.5.
About this comparison →How this year compares
Owner complaints by model year
Compare all Cooper S years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
120–25K
3425–50K
7250–75K
5675–100K
46100–150K
11150K+
231 reports with mileage · 16 unknown
NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.
What to inspect
Issues worth paying extra attention to based on owner reports.
- Steering. Review the 210 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Electrical System. Review the 19 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Visibility. Review the 12 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
7 crash reports5 fire reports2 injury reports
Steering complaints
210 reportsLOST POWER STEERING INTERMITTENTLY LAST MONTH WHILE DRIVING AND NOW THE FAN STAYS ON AND RUNS THE ENGINE TILL THE BATTERY IS DEAD. I NEED TO HAVE IT JUMPED EVERYTIME I WANT TO DRIVE IT. MINI STATED THEY WILL NOT REPLACE IT FOR FREE "THEY DON'T CARE IF THERE IS AN INVESTIGATION, UNIT WERE ORDERED TO FIX IT THE COST IS ON THE CU…
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LOST POWER STEERING INTERMITTENTLY LAST MONTH WHILE DRIVING AND NOW THE FAN STAYS ON AND RUNS THE ENGINE TILL THE BATTERY IS DEAD. I NEED TO HAVE IT JUMPED EVERYTIME I WANT TO DRIVE IT. MINI STATED THEY WILL NOT REPLACE IT FOR FREE "THEY DON'T CARE IF THERE IS AN INVESTIGATION, UNIT WERE ORDERED TO FIX IT THE COST IS ON THE CUSTOMER" *TR
2004 MINI COOPER S POWER STEERING FAILED ON I93 SOUTH ON MY WAY TO WORK IN BOSTON WITHOUT ANY WARNING , SPEED ABOUT 80 AT 4:00AM ON THE MORNING OF 4/25/2011. MADE IT TO WORK HAD CAR TAKEN IN FOR SERVICE AT MINI OF PEABODY MA THE SAME DAY AND WAS CHARGED $1180.00 DOLLARS TO REPLACE STEERING PUMP. TWO WEEKS PRIOR ON 4/8/2011 AT …
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2004 MINI COOPER S POWER STEERING FAILED ON I93 SOUTH ON MY WAY TO WORK IN BOSTON WITHOUT ANY WARNING , SPEED ABOUT 80 AT 4:00AM ON THE MORNING OF 4/25/2011. MADE IT TO WORK HAD CAR TAKEN IN FOR SERVICE AT MINI OF PEABODY MA THE SAME DAY AND WAS CHARGED $1180.00 DOLLARS TO REPLACE STEERING PUMP. TWO WEEKS PRIOR ON 4/8/2011 AT THE SAME DEALER AT THEIR RECOMMENDATION REPLACED STEERING FAN AND RETURN HOSE AS A PRECAUTION DURING ROUTINE MAINTENANCE CHARGED 500.00 DOLLARS. FRIDAY 4/22/2011 CAR WAS AT SAME DEALER TO HAVE THE CATALYTIC CONVERTER REPLACED FOLLOWED BY THEIR USUAL TEST DRIVE , THERE WAS NO MENTION OF ANY STEERING PROBLEM AT THAT TIME NOR DID I EXPERIENCE ANY PROBLEM WITH THE STEERING ON MY WAY BACK HOME AFTER REPAIR. MY CONCERN IS IF THIS HAD HAPPENED WITH OUT WARNING ON AN OFF RAMP OR WHEN MY WIFE OR DAUGHTER WERE DRIVING THE OUT COME COULD HAVE BEEN MUCH DIFFERENT. I PAID AN EXTRA 60.00 DOLLARS TO KEEP THE OLD PUMP. *TR
I HAVE A 2004 MINI COOPER S WITH APPROX 80K MILES. THE POWER STEERING RANDOMLY AND INTERMITTENTLY FAILS TO WORK. THIS PROBLEM HAS OCCURRED APPROXIMATELY SIX TIMES DURING THE LAST TWO MONTHS. I INTEND TO REPLACE THE POWER STEERING PUMP, BUT AM TOLD THAT THIS MAY HAPPEN AGAIN, EVEN WITH REPLACED PUMP. *TR
TL* THE CONTACT OWNS A 2004 MINI COOPER S. THE CONTACT WAS DRIVING 40 MPH WHEN THE POWER STEERING MALFUNCTIONED AND THE VEHICLE BECAME EXTREMELY DIFFICULT TO STEER. THE CONTACT TOOK THE VEHICLE TO A LOCAL MECHANIC WHERE HE WAS ADVISED THAT THE POWER STEERING PUMP AND THE RACK OF THE RACK AND PINION WOULD NEED REPLACING. THE MECH…
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TL* THE CONTACT OWNS A 2004 MINI COOPER S. THE CONTACT WAS DRIVING 40 MPH WHEN THE POWER STEERING MALFUNCTIONED AND THE VEHICLE BECAME EXTREMELY DIFFICULT TO STEER. THE CONTACT TOOK THE VEHICLE TO A LOCAL MECHANIC WHERE HE WAS ADVISED THAT THE POWER STEERING PUMP AND THE RACK OF THE RACK AND PINION WOULD NEED REPLACING. THE MECHANIC REPLACED BOTH THE RACK AND POWER STEERING PUMP. THE FAILURE MILEAGE WAS 70,000.
ACUTE LOSS OF POWER STEERING IN MY 2004 MINI COOPER S. I WAS DRIVING NORMALLY AND WAS PULLING ONTO THE INTERSTATE WHEN THE STEERING BECAME VERY DIFFICULT. I WAS ABLE TO CONTINUE TO STEER THE VEHICLE BUT IT REQUIRED A GREAT DEAL OF EFFORT. I'VE BEEN TOLD BY MY MECHANIC THAT IT DOESN'T INVOLVE THE FAILURE OF THE POWER STEERING PU…
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ACUTE LOSS OF POWER STEERING IN MY 2004 MINI COOPER S. I WAS DRIVING NORMALLY AND WAS PULLING ONTO THE INTERSTATE WHEN THE STEERING BECAME VERY DIFFICULT. I WAS ABLE TO CONTINUE TO STEER THE VEHICLE BUT IT REQUIRED A GREAT DEAL OF EFFORT. I'VE BEEN TOLD BY MY MECHANIC THAT IT DOESN'T INVOLVE THE FAILURE OF THE POWER STEERING PUMP FAN...THE FAN HAS BEEN TESTED AND IS WORKING OK. THE COST FOR THE REPAIR IS GOING TO BE APPROXIMATELY $1160. MY MECHANIC HAS TOLD ME THAT FAILURE OF THE P. S. PUMP IN THIS YEAR AND MODEL MINI COOPER IS COMMON. *TR
2004 MINI COOPER S. CONSUMER IS SEEKING REIMBURSEMENT FOR THE REPLACEMENT OF THE POWER STEERING PUMP. *TR
FOR THE PAST YEAR, MY MINI COOPER S HAS HAD SEVERAL SUDDEN POWER LOSSES IN THE POWER STEERING, RESULTING IN THE CAR BECOMING DIFFICULT TO CONTROL. IT HAS BEEN LOOKED AT BY A MINI SERVICE DEPARTMENT, WHO KNEW ABOUT THE PROBLEM, BUT DID NOT INFORM ME. MY WARRANTY WAS CALLED IN, AND THEY DID NOT AUTHORIZE ITS REPAIR EITHER. I LI…
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FOR THE PAST YEAR, MY MINI COOPER S HAS HAD SEVERAL SUDDEN POWER LOSSES IN THE POWER STEERING, RESULTING IN THE CAR BECOMING DIFFICULT TO CONTROL. IT HAS BEEN LOOKED AT BY A MINI SERVICE DEPARTMENT, WHO KNEW ABOUT THE PROBLEM, BUT DID NOT INFORM ME. MY WARRANTY WAS CALLED IN, AND THEY DID NOT AUTHORIZE ITS REPAIR EITHER. I LIVE IN A REMOTE AREA, WITH A DRIVING NEED FOR 3-4 HOURS FOR MEDICAL CARE. THIS DRIVE IS THROUGH CANYONS AND OVER MOUNTAINS, SO THE LOSS OF STEERING CONTROL IS IN NO WAY AN OPTION, AND MAY ALSO RESULT IN AN ACCIDENT CAUSING INJURY OR WORSE, DEATH. I HAVE DOCUMENTATION THAT THE COMPLAINT WAS MADE TO MINI BY ME, AND YESTERDAY, RECEIVED CONFIRMATION THAT THEY DID, IN FACT, KNOW ABOUT THE PROBLEM. *TR
WHILE DRIVING MY 2004 MINI COOPER S THE POWER ASSISTED STEERING SEEMS TO QUIT WORKING. THIS HAS HAPPENED IN THE PAST AND THEN THE POWER ASSIST BEGINS WORKING ON ITS OWN AND MAY WORK FOR QUITE A WHILE THEN UNEXPECTEDLY WILL STOP WORKING AGAIN. WHEN THIS HAPPENS THE STEERING BECOMES VERY DIFFICULT AND REQUIRES A GREAT DEAL OF EX…
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WHILE DRIVING MY 2004 MINI COOPER S THE POWER ASSISTED STEERING SEEMS TO QUIT WORKING. THIS HAS HAPPENED IN THE PAST AND THEN THE POWER ASSIST BEGINS WORKING ON ITS OWN AND MAY WORK FOR QUITE A WHILE THEN UNEXPECTEDLY WILL STOP WORKING AGAIN. WHEN THIS HAPPENS THE STEERING BECOMES VERY DIFFICULT AND REQUIRES A GREAT DEAL OF EXTRA EFFORT TO TURN. MANY TIMES IT ONLY STOPS WORKING FOR ONE OR TWO TURNS THEN THE POWER ASSIST PUMP BEGINS WORKING AGAIN. IN THE FALL OF 2010 I HAD TO INSTALL A POWER STEERING PUMP "COOLING FAN" BECAUSE IT FAILED BUT THE PUMP CONTINUES TO INTERMITTENTLY STOP WORKING.
TL* THE CONTACT OWNS A 2004 MINI COOPER S. WHILE DRIVING APPROXIMATELY 40 MPH, THE STEERING WHEEL BECAME VERY STIFF AND DIFFICULT TO TURN. THE CONTACT ALSO STATED THAT THE STEERING WHEEL WAS STUCK IN A PARTIALLY TURNED POSITION BUT THE VEHICLE CONTINUED TO DRIVE STRAIGHT FORWARD. THE VEHICLE WAS TOWED TO THE CONTACTS PLACE OF RE…
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TL* THE CONTACT OWNS A 2004 MINI COOPER S. WHILE DRIVING APPROXIMATELY 40 MPH, THE STEERING WHEEL BECAME VERY STIFF AND DIFFICULT TO TURN. THE CONTACT ALSO STATED THAT THE STEERING WHEEL WAS STUCK IN A PARTIALLY TURNED POSITION BUT THE VEHICLE CONTINUED TO DRIVE STRAIGHT FORWARD. THE VEHICLE WAS TOWED TO THE CONTACTS PLACE OF RESIDENCE AND WAS NEITHER DIAGNOSED NOR REPAIRED FOR THE FAILURE. THE FAILURE AND CURRENT MILEAGES WERE 105,683.
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).