The 2004 MINI Cooper has 4 safety recalls and 282 owner complaints on file with NHTSA. The most-reported problem area is steering (247 complaints).
Recalls4safety recalls
Complaints282filed by owners
Crashes · fires5 · 9reported in complaints
Injuries · deaths1 · 1reported in complaints
2004 MINI Cooper in an NHTSA crash test
Safety recalls
Steering › Electric power assist system
NHTSA recall 15V660000 · Oct 15, 2015 · 86,018 vehicles · opened 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.
Exterior lighting › Headlights
NHTSA recall 09E025000 · May 11, 2009 · 42,540 vehicles · opened after NHTSA action (OVSC)
Problem: DOPE, INC. IS RECALLING 42,540 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THESE LAMPS DO NOT CONTAIN THE REQUIRED AMBER SIDE REFLECTORS.
Risk: DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.
Fix: DOPE, INC. WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAMPS. THE SAFETY RECALL BEGAN ON JULY 28, 2009. OWNERS MAY CONTACT DOPE, INC. AT 1-626-272-1798.
Exterior lighting › Headlights
NHTSA recall 08E050000 · Aug 11, 2008 · 1,921 vehicles · opened after NHTSA action (OVSC)
Problem: K2 MOTOR IS RECALLING 1,921 AFTERMARKET HEADLAMPS OF VARIOUS MODELS SOLD FOR USE ON THE ABOVE LISTED VEHICLES. THESE HEADLAMPS ARE MISSING THE AMBER SIDE REFLEX REFLECTOR WHICH FAILS TO CONFORM WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT."
Risk: WITHOUT THE AMBER SIDE REFLEX REFLECTORS, THE LIGHTING VISIBILITY MAY BE AFFECTED, POSSIBLY RESULTING IN A VEHICLE CRASH.
Fix: K2 MOTOR WILL NOTIFY OWNERS AND OFFER A FULL REFUND. THE RECALL BEGAN ON DECEMEBER 17, 2008. OWNERS MAY CONTACT K2 MOTOR AT 1-909-839-2992.
Tires › Pressure monitoring and regulating systems
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
NHTSA side barrier crash test
2004 MINI Cooper w/SAB
Overall
Not 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
28mpg combined
City / highway
25 / 33 mpg
Fuel
Premium Gasoline
1.6 L · 4 cyl · Manual 5-spd · Front-Wheel Drive · about $2,950/year to fuel
Cooper
25mpg combined
City / highway
22 / 29 mpg
Fuel
Premium Gasoline
1.6 L · 4 cyl · Automatic (variable gear ratios) · 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*
Steering Hydraulic power assist › Pump; Electric power assist system
247
3
5
0
74,600 mi
Power train Automatic transmission; Manual transmission
27
0
1
0
62,000 mi
Electrical system
15
0
6
0
65,000 mi
Visibility Windshield; Power window devices and controls
7
0
0
0
35,500 mi
Engine and engine cooling Cooling system › Fan; Exhaust system › Manifold/header/muffler/tail pipe
6
0
1
1
55,497 mi
Suspension Rear; Front
4
0
0
0
60,000 mi
Engine
4
0
0
0
70,999 mi
Structure Body
3
0
1
0
—
Unknown or other
3
1
1
0
—
Tires Pressure monitoring and regulating systems
2
0
0
0
—
Wheels
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
Aug 30, 2024 · 160,000 milesSteering The contact owns a 2004 Mini Cooper. The contact received notification of NHTSA Campaign Number: 15V660000(STEERING); however, the part to do the recall repair was unavailable. The local dealer was contacted, and it was confirmed that the part was not available. The contact stated that the manufacturer exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The contact had experienced the failure, causing the driver to lose control of the steering and drive off the road. The exact cause of the failure was not determined, and the vehicle was not repaired. The manufacturer and local dealer were notified of the failure. The failure mileage was…
Apr 24, 2022 · crashSteering Mini felt like it was getting pushed by the wind . Realized wasn't wind Mini loss of completely all functions of steering wheel. On super busy highway. Devine intervention Was in far left car went left to right lanes then hit median gaurd rail spun around Finally got it to stop. Never Hitting and hurting anyone around me. Nobody hit me. Car is totalled ! Still at tow place. I saw my life flash as cars were zooming by me. Someone should be held responsible for my car and almost my life. Called out of work can't move upper body that well.
Sep 6, 2019 · 135,000 miles · crash · fireUnknown or other MY WIFE WAS DRIVING OUR 2004 MINI COOPER HOME TRAVELING UPHILL ON A STEEP PAVED MOUNTAIN ROADWAY TRAVELING A MAXIMUM OF 15 MPH WHEN FOR SOME UNKNOWN REASON THE VEHICLE LEFT THE ROADWAY; STRUCK A TREE WITH ITS LEFT FRONT AND BURST INTO AN EXPLODING FIRE KILLING MY WIFE WHO WAS NOT ABLE TO ESCAPE THE BURNING VEHICLE. THE NC STATE POLICE ARE INVESTIGATING THE CAUSE OF THE FIRE AND DEATH. THEY DO NOT KNOW YET WHETHER THE VEHICLE CAUGHT FIRE PRIOR TO STRIKING THE TREE BUT, FEEL THE FIRE COULD NOT HAVE BEEN CAUSED BY THE VEHICLE STRIKING THE TREE AT A LOW IMPACT AND SPEED. NC MV ACCIDENT REPORT#[XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TT
Apr 29, 2019 · 201,000 milesSteering MAINLY WHILE COLD AND AT LOW SPEED'S THE WHEEL SUDDENLY BECOMES VERY HARD TO TURN AND I WAS TOLD BY A MECHANIC BUT IT'S A FAULTY HYDRAULIC POWER STEERING PROBLEM
Apr 28, 2019 · 200,000 milesSteering VERY HARD TO TURN STEERING WHEEL AT TIMES ESPECIALLY WHEN MOVING SLOWLY; COMING TO A TURN AT A LIGHT, BACKING OUT OF A PARKING SPOT, ETC.
Nov 23, 2018 · 62,000 milesFuel/propulsion system 2004 MINI COOPER PURCHASED NEW APROX 62 MILES ON IT AND THE CVT TRANSMISSION IS GONE & THERE WAS A CLASS ACTION LAWSUIT FOR THE REPLACEMENT OF THIS, I WAS NEVER NOTIFIED AND WANT THIS FIXED AT NO COST TO ME. AT APROX. 50 TO 60 MPH THE CAR ENGINES GOES WAY BEYOND THE PROPER RPM.
Aug 1, 2017Steering TL* THE CONTACT OWNS A 2004 MINI COOPER. THE CONTACT STATED THAT THE STEERING WHEEL WAS DIFFICULT TO TURN IN EITHER DIRECTION. THE ELECTRIC POWER STEERING WARNING INDICATOR WAS NOT ILLUMINATED. AN UNKNOWN DEALER WAS CONTACTED AND STATED THAT THE VEHICLE WAS NOT UNDER WARRANTY, AND WAS EXCLUDED FROM NHTSA CAMPAIGN NUMBER: 15V660000 (STEERING) AND NHTSA ACTION NUMBERS: EA11005 (STEERING) AND PE10038 (STEERING). THE MANUFACTURER WAS NOTIFIED AND DID NOT ASSIST. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE FAILURE MILEAGE WAS NOT AVAILABLE.
Jul 28, 2015 · 20 milesSteering POWER STEERING HAS BEEN AN ISSUE OVER A YEAR OR TWO. NO TOTAL FAILURES BUT IT DOES NOT QUALIFY AS POWER STEERING. THE COOLING FAN DOES NOT WORK. STEERING IS NOT GOOD....FOR POWERED STEERING THAT IS. SLOW SPEED STEERING IS HORRENDOUS AND NON EXISTENT.
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
EA11005 · opened May 4, 2011 · closed Jan 5, 2016 · led to recall 15V660000Loss of power steering assist 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…
PE10038 · opened Sep 24, 2010 · closed May 10, 2011Loss of Power Steering Assist 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…
