IllustrationPOWER STEERING WENT COMPLETELY OUT ON MY WIFE'S 2005 MINI COOPER. NO WARNING, INDICATIONS, OR EVENTS LED UP TO FAILURE. *TR
2005 Mini Cooper
Owner reports · Recalls · Investigations
More warning signs than most Cooper years
Owner complaints for the 2005 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
220–25K
5925–50K
11050–75K
9375–100K
52100–150K
11150K+
347 reports with mileage · 25 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 276 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Air Bags. Review the 41 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Electrical System. Review the 30 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
8 crash reports10 fire reports1 injury reports
What owners actually said
372 reportsPOWER STEERING PUMP ON 2005 MINI COOPER CONVERTIBLE STARTED MAKING NOISE (EVEN WITH ENGINE TURNED OFF, DRAINING THE BATTERY), THEN ULTIMATELY FAILED. AN INTERNET SEARCH INDICATES THAT THIS REPAIR COSTS APPROX $2000 TO FIX, AND THAT REPLACEMENT POWER STEERING PUMPS FAIL REGULARLY, SO WE'VE BEEN DRIVING WITHOUT POWER STEERING…
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POWER STEERING PUMP ON 2005 MINI COOPER CONVERTIBLE STARTED MAKING NOISE (EVEN WITH ENGINE TURNED OFF, DRAINING THE BATTERY), THEN ULTIMATELY FAILED. AN INTERNET SEARCH INDICATES THAT THIS REPAIR COSTS APPROX $2000 TO FIX, AND THAT REPLACEMENT POWER STEERING PUMPS FAIL REGULARLY, SO WE'VE BEEN DRIVING WITHOUT POWER STEERING IN THE VEHICLE. *TR
I COMPLAINED TO MINI COOPER DEALERSHIP ABOUT NOISE COMING FROM UNDERSIDE OF THE ON MULTIPLE OCCASIONS. THEY WERE NEVER ABLE TO FIND THE PROBLEM AND THE LAST TIME I COMPLAINED THEY BLAMED IT ON "WORN TIRES". AT 52,000 MILES I NOTICED A HIGH PITCH SQUEALING FROM UNDER THE CAR WHEN I HAD THE CLUTCH PRESSED IN. WHEN I BROUGHT IT …
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I COMPLAINED TO MINI COOPER DEALERSHIP ABOUT NOISE COMING FROM UNDERSIDE OF THE ON MULTIPLE OCCASIONS. THEY WERE NEVER ABLE TO FIND THE PROBLEM AND THE LAST TIME I COMPLAINED THEY BLAMED IT ON "WORN TIRES". AT 52,000 MILES I NOTICED A HIGH PITCH SQUEALING FROM UNDER THE CAR WHEN I HAD THE CLUTCH PRESSED IN. WHEN I BROUGHT IT TO MINI SERVICE, THEY SAID THAT "CLUTCH MATERIAL PROBABLY GOT CAUGHT IN THE FINGERS OF THE CLUTCH". THEY SAID THAT SINCE MY WARRANTY WAS UP (OVER AT 50,000 MILES) AND THAT THIS WAS A "FRICTION MATERIAL" ISSUE, THE COST OF THE REPAIR ($2,200 - $2,800) WOULD BE MY RESPONSIBILITY. SINCE THIS COST WAS SO HIGH AND THE EARLY FAILURE SO FAR OUTSIDE OF NORMAL EXPECTED DUTY TIME, I REFUSED THE SERVICE. SINCE THERE ARE MANY REPORTED CASES OF EARLY CLUTCH FAILURE AND FLYWHEEL FIELD UPGRADES, I CONTACTED MINI USA AND ASKED FOR MY ISSUE TO BE REVIEWED AS A WARRANTY ISSUE. THEY WOULD NOT AGREE TO COVER THE REPAIR, BUT SAID I WOULD HAVE TO PAY AT LEAST $700 TO CHECK OUT TO EVEN CONSIDER THIS AS A WARRANTY. THEY WOULD NOT ALLOW ME TO BRING THE CAR TO AN INDEPENDENT SHOP FOR REVIEW. SINCE INDEPENDENT SHOPS CHARGE ABOUT HALF THE AMOUNT FOR CLUTCH REPLACEMENT, I WANTED THAT OPTION IN CASE MINI REFUSED TO COVER ANY COSTS. THE MINI CS REFERENCE NUMBER FOR THIS ISSUE IS 2000736002924. ON 12/25 (CHRISTMAS DAY) MY CLUTCH FAILED COMPLETELY. SINCE MINI IS NOT WILLING TO GIVE ANY MATERIAL SUPPORT TO THIS ISSUE, AND THERE ARE MANY OTHER CASES OF EARLY CLUTCH FAILURE REPORTED I OPENED THIS COMPLAINT TO SEE IF NHTSA COULD HELP RESOLVE THIS PROBLEM. *TR
ABSOLUTELY NO UNUSUAL NOISES OR ANY OTHER SYMPTOMS LEADING UP TO THE FAILURE. CAR HAS ABOUT 53,000 MILES ON IT, POWER STEERING PUMP FAILED- CAR IS NOW EXCEEDINGLY DIFFICULT TO STEER & A SAFETY HAZARD TO DRIVE. THANKFULLY I WAS DRIVING AT LOW SPEED WHEN THE FAILURE OCCURRED, SO NO CRASHES OR INJURIES OCCURRED. POWER STEERING P…
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ABSOLUTELY NO UNUSUAL NOISES OR ANY OTHER SYMPTOMS LEADING UP TO THE FAILURE. CAR HAS ABOUT 53,000 MILES ON IT, POWER STEERING PUMP FAILED- CAR IS NOW EXCEEDINGLY DIFFICULT TO STEER & A SAFETY HAZARD TO DRIVE. THANKFULLY I WAS DRIVING AT LOW SPEED WHEN THE FAILURE OCCURRED, SO NO CRASHES OR INJURIES OCCURRED. POWER STEERING PUMP & FAN WILL NEED TO BE REPLACED, BUT HAVE NOT HAD IT DONE YET, AS I AM TOLD IT WILL COST APPROXIMATELY $1500 FOR THIS REPAIR & I AM ABOUT 3000 MILES OUT OF WARRANTY NOW. I HAVE ALSO HEARD THIS IS A COMMON PROBLEM IN 2002-2006 MINI COOPERS. *TR
COMPLETE CATASTROPHIC FAILURE OF THE FRONT PASSENGER STRUT, STRUT TOWER, MOUNT AND LOWER CONTROL ARM BUSHING CAUSED BY AN IMPERFECTION ON A PUBLIC, WELL TRAVELED ROAD. REPORTS ON ENTHUSIAST FORUMS OF OVER 216 OTHERS SUFFERING THE SAME FAILURE ON THE SAME MODEL CAR AND A REPORT IN THE SEPT-OCT 2007 EDITION OF MC2 MAGAZINE CITING …
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COMPLETE CATASTROPHIC FAILURE OF THE FRONT PASSENGER STRUT, STRUT TOWER, MOUNT AND LOWER CONTROL ARM BUSHING CAUSED BY AN IMPERFECTION ON A PUBLIC, WELL TRAVELED ROAD. REPORTS ON ENTHUSIAST FORUMS OF OVER 216 OTHERS SUFFERING THE SAME FAILURE ON THE SAME MODEL CAR AND A REPORT IN THE SEPT-OCT 2007 EDITION OF MC2 MAGAZINE CITING THE NEED TO LOOK FOR THESE COMMON FLAWS ON THIS MODEL CAR WHEN CONSIDERING PURCHASING A USED ONE.
OUR 2005 MINI COOPER S HAS BEEN PLAGUED WITH AN ENGINE PROBLEMS SINCE WE FIRST PURCHASED IT IN JULY OF 2005. WHILE DRIVING, THE ENGINE SUDDENLY LOSES POWER CAUSING THE VEHICLE TO STOP SUDDENLY. THIS PROBLEM HAS OCCURRED WHILE DRIVING AT A SPEED OF 65 MPH ON A MAJOR HIGHWAY. WE'VE CONTACTED THE DEALER A NUMBER OF TIMES AND REQUES…
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OUR 2005 MINI COOPER S HAS BEEN PLAGUED WITH AN ENGINE PROBLEMS SINCE WE FIRST PURCHASED IT IN JULY OF 2005. WHILE DRIVING, THE ENGINE SUDDENLY LOSES POWER CAUSING THE VEHICLE TO STOP SUDDENLY. THIS PROBLEM HAS OCCURRED WHILE DRIVING AT A SPEED OF 65 MPH ON A MAJOR HIGHWAY. WE'VE CONTACTED THE DEALER A NUMBER OF TIMES AND REQUESTED SERVICE APPOINTMENTS. WE HAVE BEEN TOLD EACH TIME THAT IT IS NOT NECESSARY TO BRING THE CAR IN AND THAT THE PROBLEM IS BEING CAUSED BY A LOOSE GAS CAP. LIVING IN THE STATE OF NJ WHERE YOU CANNOT PUMP YOUR OWN GAS, WE CONSISTENTLY REMIND THE GAS ATTENDANT TO PROPERLY ATTACH THE GAS CAP AND WE CHECK THE CAP AFTER GETTING GAS. THE PROBLEM IS STILL OCCURRING. HOWEVER, REGARDLESS OF WHETHER OR NOT THE PROBLEM IS BEING CAUSED BY THE GAS CAP, THIS IS A HUGE SAFETY HAZARD. MY WIFE WAS 8 MONTHS PREGNANT AND DRIVING THE CAR ON THE HIGHWAY ONE OF THE FIRST TIMES THIS OCCURRED. SHE WAS STUCK IN ONCOMING TRAFFIC FOR 10 MINUTES WHILE TRYING TO GET THE VEHICLE RESTARTED. IF THIS PROBLEM IS NOT ADDRESSED VERY SOON, SOMEONE IS GOING TO BE SERIOUSLY INJURED. *JB
WINDSHIELD SPONTANEOUSLY CRACKED. CRACK STARTED AT TOP CENTER EXTENDED DOWN ABOUT 4 INCHES, THEN HORIZONTALL FOR ABOUT 4 INCHES AND IS NOW MOVING DOWN AGAIN. *NM
CRACKED WINDSHIELD 2005 MINI COOPER S. *JB
MY 2005 MINI COOPER S AUTOMATIC SUDDENLY STOPPED TWICE FOR NO APPARENT REASON WHILE DRIVING. CAR WAS ONLY 4 MONTHS OLD, ABOUT 4000 MILES ON CAR. I WAS ACTUALLY IN MOTION, AND THE CAR JUST STOPPED MOVING! I HAD TO TURN OFF THE CAR AND RESTART IT. EML AND CHECK ENGINE LIGHTS CAME ON ONCE THE CAR STOPPED. THE CHECK ENGINE LIG…
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MY 2005 MINI COOPER S AUTOMATIC SUDDENLY STOPPED TWICE FOR NO APPARENT REASON WHILE DRIVING. CAR WAS ONLY 4 MONTHS OLD, ABOUT 4000 MILES ON CAR. I WAS ACTUALLY IN MOTION, AND THE CAR JUST STOPPED MOVING! I HAD TO TURN OFF THE CAR AND RESTART IT. EML AND CHECK ENGINE LIGHTS CAME ON ONCE THE CAR STOPPED. THE CHECK ENGINE LIGHT STAYED ON FOR A FEW DAYS, THEN WENT OFF, SO I ASSUMED IT WAS A FLUKE AND NOTHING TO WORRY ABOUT (OTHERWISE I ASSUME THE LIGHT WOULD STAY ON). THE SECOND TIME IT HAPPENED WAS EXACTLY THE SAME SCENARIO AS THE FIRST. I HAVE SINCE LEARNED THAT MINI IS CALLING THIS "LIMP MODE", BUT I HAD NEVER RECEIVED ANY RECALL NOTIFICATION FROM MINI, OR ANYTHING INDICATING THAT THEY KNEW ABOUT THIS PROBLEM. HOWEVER, THE DID KNOW, BASED ON WHAT I HAVE READ OF OTHERS WHO COMPLAINED TO THEM ABOUT THE EXACT SAME PROBLEMS!! YET MINI APPARENTLY DID NOT NOTIFY DEALERSHIPS, BECAUSE THE FIRST ONE I CALLED HAD NO IDEA WHAT THE PROBLEM WAS WHICH I DESCRIBED, AND WASN'T GOING TO TAKE ME FOR SERVICE UNTIL 2 WEEKS LATER. I CALLED A SECOND DEALER WHO IMMEDIATELY KNEW THE PROBLEM, AND SAID IT WAS A VOLUNTARY RECALL. STILL I HAD NOT HEARD ANYTHING FROM MINI USA. I TOOK MY CAR IN AND IT WAS FIXED IN AN HOUR--THEY REPROGRAMMED THE DME. THIS IS A SAFETY ISSUE! I STILL HAVEN'T HEARD ANYTHING FROM MINI ABOUT A SAFETY RECALL FOR THIS PROBLEM! MAYBE THEY DIDN'T NOTIFY ME BECAUSE I HAD IT TAKEN CARE OF ALREADY, BUT HAD THIS HAPPENED ON THE FREEWAY, RATHER THAN IN MY NEIGHBORHOOD, I COULD BE DEAD NOW! WHY ISN'T MINI NOTIFYING OWNERS WHO PURCHASED THE 2005 AUTOMATICS!! WHY AREN'T THEY ISSUING A RECALL? ARE THEY WAITING FOR SOMEONE TO BE KILLED? *JB
CONSUMER HAD 2005 MINI COOPER IN SHOP FOR COLLISION REPAIRS THAT WERE NOT MADE. *TS THE CONSUMERS VEHICLE HAD BEEN AT THE BODY SHOP FOR OVER 2 MONTHS, BECAUSE THE AUTO BODY SHOP RECEIVED THE WRONG PART 3 TIMES. *JB
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.
15V205000 · Air Bags:frontal
Apr 6, 2015
BMW of North America, LLC (BMW) is recalling certain model year 2005-2006 MINI Cooper and Cooper S vehicles manufactured January 5, 2005, to November 28, 2006, and 2005-2008 MINI Cooper Convertible and Cooper S Convertible vehicles manufactured January 5, 2005, to July 31, 2008. Due to manufacturing, installation, and exposure issues, the front passenger seat occupant detection mat may not function properly and, as a result, the front passenger air bag may not deploy in a crash.
Consequence & remedy
Consequence: An improperly functioning mat may cause the passenger frontal air bag to be inactive when the seat is occupied, and in the event of a crash, the air bag will not deploy, increasing the passenger's risk of injury.
Remedy: MINI will notify owners, and dealers will replace the front passenger seat occupant detection mat, free of charge. The recall began on October 12, 2015. Owners may contact MINI customer service at 1-866-825-1525.
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).