Model year record

2004 MINI Cooper S recalls & problems

The 2004 MINI Cooper S has 2 safety recalls and 247 owner complaints on file with NHTSA. The most-reported problem area is steering (215 complaints).

Recalls2safety recalls

Complaints247filed by owners

Crashes · fires7 · 5reported in complaints

Injuries · deaths3 · 0reported in complaints

Safety recalls

SteeringOct 15, 2015

Electric power assist system

Recall 15V66000086,018 vehiclesopened after NHTSA action (ODI)

Problem: 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.
Risk: 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.
Fix: 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.

TiresJul 12, 2004

Pressure monitoring and regulating systems

Recall 04V3480001,193 vehicles

Problem: 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.
Risk: 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.
Fix: 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.

Recall repairs are free at any authorised dealer. A recall listed here may already have been fixed on a particular car: enter its 17-character VIN at nhtsa.gov/recalls to see open recalls.

Crash test ratings

2004 MINI Cooper S w/SAB

OverallNot Rated

Frontal crash	Not Rated
Side crash	Not Rated
Rollover	Not Rated

NHTSA 5-Star Safety Ratings (New Car Assessment Program). Ratings are comparable only between vehicles of similar size and weight, and ratings from 2011 on use tougher tests than earlier years. Photos: NHTSA.

Fuel economy

Cooper S

25mpg combined

City / highway	22 / 31 mpg
Fuel	Premium Gasoline

1.6 L · 4 cyl · Manual 6-spd · Front-Wheel Drive · about $3,300/year to fuel

EPA estimates from fueleconomy.gov for each engine and transmission sold. Annual cost is the EPA's estimate for 15,000 miles a year at its current fuel and electricity price assumptions. Your results will vary.

What owners report

Problem area	Complaints	Crashes	Fires	Injuries	Typical mileage*
SteeringHydraulic power assist › Pump; Electric power assist system	215	7	3	2	78,000 mi
Electrical systemWiring › Fuses and circuit breakers	19	0	2	1	79,330 mi
VisibilityWindshield; Power window devices and controls	12	0	0	0	23,052 mi
Air bags	8	0	0	0	80,000 mi
Engine and engine cooling	3	0	0	0	60,950 mi
Seat beltsFront › Buckle assembly	3	0	0	0	80,000 mi
SeatsFront assembly › Seat heater/cooler	3	0	1	1	70,000 mi
WheelsLugs/nuts/bolts/studs	2	0	0	0	—
Power trainManual transmission	2	0	0	0	—
Latches/locks/linkages	2	0	0	0	—
Tires	2	0	0	0	—
Electronic stability control (esc)	2	0	1	0	—

*Median odometer reading when the problem happened, where owners gave one. One complaint can name several problem areas.

Recent owner complaints

Electronic stability control (esc)
WAS DRIVING CAR ON 18 JULY 2020 AND POWER STEERING QUIT WORKING AND MADE STEERING DIFFICULT, ALSO COOLANT FAN,LOW SPEED AND HIGH SPEED STOPPED WORKING SAME TIME AS POWER STEERING QUIT. THE ASC LIGHT CAME ON AND IT WILL NOT TURN OFF. NO BLOWN FUSES IN ENGINE COMPARTMENT OR BY DRIVERS KICK PANEL. I WAS DRIVING THE CAR ON A STATE ROAD WHEN THIS OCCURRED.
Jul 18, 2020 · 116,543 miles
Steering
TL* THE CONTACT OWNS A 2004 MINI COOPER S. THE CONTACT STATED THAT WHILE DRIVING AT ATTEMPTING TO MAKE A TURN, THERE WAS AN ABNORMAL GRINDING SOUND COMING FROM THE STEERING COLUMN. THE CONTACT ALSO STATED THAT THERE WAS A POWER STEERING FLUID LEAK PRESENT. THE FAILURE WAS INTERMITTENT. THE VEHICLE WAS TAKEN TO MINI OF STEVENS CREEK LOCATED AT (4201 STEVENS CREEK BLVD, SANTA CLARA, CA 95051), AND DIAGNOSED. THE CONTACT WAS INFORMED THAT THE STEERING PUMP NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 156,000.
Feb 29, 2020 · 156,000 miles
Electrical system
THE POWER STEERING IS VERY STIFF TO DRIVE AND CANNOT DRIVE MY COOPER BECAUSE I CAN NO LONGER STEER THE VEHICLE.
Dec 13, 2019
Steering
WHEN YOU TURN WHEEL LEFT OR RIGHT IT MAKES A NOISE AND IT'S VERY HARD TO TURN. SO I THINK IT'S THE STEERING: ELECTRIC POWER ASSIST SYSTEM. RECALL ID # 240625.
Nov 24, 2019
Air bags
ALL MODELS FROM 2005 ONWARD HAVE BEEN RECALLED, YET EARLIER MODELS HAVE THE SAME PROBLEMS WITH NON FUNCTIONING AIRBAGS. THE AIRBAG WARNING LIGHT IS ON CONTINUALLY, AND THERE ARE KNOWN PROBLEMS WITH WIRING, PRESSURE MATS AND CONNECTORS IN THESE VEHICLES. BMW IS INTENTIONALLY IGNORING THESE ISSUE. MY OWN PERSONAL VEHICLE HAS THIS PROBLEM AND AS A GOVERNMENT MANDATED SAFETY DEVICE I BELIEVE THAT EARLIER MODELS OF MINI COOPERS SHOULD BE INCLUDED IN THE RECALL!
Jun 30, 2019
Air bags
AIRBAG LIGHT COMES ON AND STAYS ILLUMINATED. WE ARE UNSURE IF THE SYSTEM IS WORKING PROPERLY. WE HAVE NOT RUN DIAGNOSTIC CODES ON THE SYSTEM.
Jun 11, 2018 · 121,348 miles
Electronic stability control (esc)Fire
THE VEHICLE WAS HARD TO STEER AND SMOKE WAS COMING FROM THE ENGINE. TOOK THE CAR HOME, DID NOT SEE FLAMES, PARKED CAR IN THE DRIVEWAY SWITCHED CARS AND LEFT. RECEIVED A CALL FROM THE FIRE DEPARTMENT THAT MY MINI WAS ON FIRE AND I NEEDED TO RETURN TO MY HOUSE.
Aug 6, 2017 · 165,000 miles
Steering
THE POWER STEERING IN MY 2004 MINI COOPER S FAILED LAST MONTH, PROMPTING ME TO RESEARCH WAYS TO FIX THE VEHICLE ONLINE. I FOUND THAT MINI USA HAD ISSUED A RECALL ON MY CAR, BUT WAS INFORMED BY THE DEALERSHIP AND THEN MINI THAT MY VIN NUMBER DID NOT FALL AMONG THOSE VEHICLES RECALLED. I'M WONDERING WHETHER MINI APPROPRIATELY LIMITED THEIR RECALL CONSIDERING MY VEHICLE HAS THE SAME PROBLEM THAT PROMPTED THE RECALL, AND FALLS WITHIN THE SAME MODEL AND YEAR RANGE. I THINK THE DEPARTMENT SHOULD INVESTIGATE WHETHER TO EXPANDING THE RECALL.
Jul 6, 2017 · 84,000 miles

Owner complaints are submitted to NHTSA by the public and are not verified. Shown as filed (NHTSA removes personal details); long reports are shortened.

NHTSA defect investigations

Loss of power steering assistClosedLed to recall 15V660000
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…
EA11005 · opened May 4, 2011 · closed Jan 5, 2016
Loss of Power Steering AssistClosed
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…
PE10038 · opened Sep 24, 2010 · closed May 10, 2011