2003 MINI COOPER S Complaints

THE WINDSHIELD OF MY 2003 MINI COOPER S HAD THREE SIGNIFICANT CRACKS AND MULTIPLE CHIPS WITHIN A YEAR OF OWNERSHIP.*AK

PARKED VEHICLE OUTSIDE GROCERY STORE. RETURNED AFTER <5 MINUTES TO FIND SMOKE POURING FROM THE HOOD. OPENED HOOD TO DETERMINE CAUSE AND SMELT ELECTRICAL SMOKE, AND SAW FLAMES COMING FROM UNDER THE ENGINE. DOUSED FLAMES USING A FIRE EXTINGUISHER FROM STORE, AND DISCONNECTED BATTERY. INITIAL DEALER INVESTIGATION INDICATES THAT THE DAMAGE WAS TO THE POWER STEERING PUMP AND WIRING HARNESS. HAD I NOT STOPPED FOR GROCERIES, I WOULD HAVE BEEN UNLIKELY TO NOTICE THE SMOKE/FIRE EARLY ENOUGH TO PREVENT THE LOSS OF THE VEHICLE. INSURANCE AND DEALER ROOT CAUSE INVESTIGATION IS STILL PENDING, BUT AFTER SOME RESEARCH ON THE INTERNET (MOSTLY HTTP://WWW.NORTHAMERICANMOTORING.COM/FORUMS/SHOWTHREAD.PHP?T=73527) I FOUND AT LEAST 10 OTHER INSTANCES OF A FAULT IN THE POWER STEERING PUMP CAUSING FIRES. BMW IS OBVIOUSLY AWARE OF SOME OF THESE PROBLEMS, AS THEY MADE CHANGES TO THE POWER STEERING PUMP AND POWER STEERING FAN WIRING HARNESS IN 04 MODELS ON. IT SEEMS TO ME THAT THERE IS A SYSTEMATIC PROBLEM WITH THE POWER STEERING PUMP ON MINIS. NO FUSE BLEW, AND TO HAVE AN ELECTRICAL COMPONENT RUN TO THE POINT WHERE IS COMBUSTS, WITHOUT ANY FUSE OR THERMAL FUSE PROTECTION SEEMS A GROSS DESIGN DEFICIENCY TO ME. *NM

AFTER READING INTERNET FORUMS REGARDING THE MINI COOPER CARS. I LEARNED OF A RECURRING PROBLEM WITH THE FRONT STRUT TOWERS DEFORMING UNDER REGULAR DRIVING CONDITIONS. UPON INSPECTION OF MY OWN MINI COOPER BY MYSELF I FOUND THAT MY TOWERS WERE DISTORTED IN A MUSHROOMING OF THE TOP SHEET METAL . I FOUND ONLINE THE MANUFACTURER OF A MACHINED ALUMINUM PLATE THAT BOLTS ON TOP OF THE TOWER ADDING ADDITIONAL STRENGTH TO THE TOP OF THE TOWER. MY VEHICLE DID NOT HAVE CRACKS IN THE TOWER BUT OTHER PEOPLE ARE FINDING CRACKS AS WELL AS THE DISTORTION. I BELIEVE THAT IF THE TOWER WHERE TO CRACK COMPLETELY THAT THE FRONT STRUTS WOULD BE FORCED UP AND CAUSING THE CAR TO LOOSE THE ABILITY TO CONTROL STEERING. *NM

RUST IS DEVELOPING ON THE SHEET METAL ON BOTH THE DRIVER SIDE AND PASSENGER SIDE BODY FRAME COVERED BY THE RUBBER DOOR SEAL. THIS RUST IS IN AN AREA THAT IS UNPAINTED (BARE SHEET METAL). THE RUBBER DOOR SEAL TRAPS MOISTURE AGAINST THE STEEL. *NM

ONE MORNING DRIVING ABOUT 100 MPH GOING UP TO CT I PAY A TOLL TAKE OFF THE CAR HESITATES IN FIRST GEAR THEN GOES OK ABOUT A 2 MILES FROM THE TOLL I AM DOING ABOUT 100 MPH AND SWITCH TO THE RIGHT LANE AND THE CAR JUST STOP GIVING ME POWER SO I GO TO CHANGE TO 5TH GEAR NO LUCK SO I LET THE CAR ROLL TO THE SHOULDER CALL MINI ROADSIDE AND THEY TOW TO NEAREST DEALER TO MY HOUSE. THE DEALER HAS MY CAR FOR A TOTAL OF 8 DAYS AND TELL ME THE L/FRONT AXLE WILL NOT STAY IN THE TRANSMISSION. THEN THE DEALER SAY THAT ITS NOT COVERED@ FIRST THEN TELLS ME THAT WILL COVER IT A DAY LATER AFTER THE MINI SPECIALIST TAKE A LOOK @ IT AND SAY WE WILL COVER IT THIS TIME AS A FAVOR. NOW IT IS TEN DAYS LATER AND THE SAME THING HAS HAPPEN AGAIN THIS TIME I HAVE TO PAY FOR TOWING AND I CANT WAIT TO HAVE A TALK WITH THE DEALER. I WILL KEEP U GUYS POSTED. *NM

JUST DRIVING ALONG ON A STRAIGHT SMOOTH ROAD AT 40 MPH WHEN THE LOWER REAR CONTROL ARM BROKE CLEAN IN HALF NEARLY CAUSING ME TO LOSE CONTROL OF THE CAR AS THE WHEEL ROTATED UP INTO THE FENDER WELL. SCOTTSDALE MINI INSISTS THAT THIS ARM SHOULD ONLY BREAK IF THE CAR WAS CRASHED AND THEREFORE THEY WILL NOT HONOR THE WARRANTY. I AM THE ORIGINAL OWNER AND HAVE NEVER HIT ANY SIGNIFICANT POTHOLES OR OTHER ROAD HAZARDS. THERE ARE MANY SIMILAR CASES OF THIS FAILURE REPORTED ON THE INTERNET BUT MINI IS APPARENTLY RELUCTANT TO CLASSIFY IT AS A DESIGN FLAW. *JB

ON 1/26/06 I TOOK MY CAR INTO TUFFY AUTO TO HAVE THE TIRES ROTATED, AT THE TIME THE MECHANIC TOLD ME THAT THE RIGHT REAR LOWER CONTROL ARM HAD A CRACK IN IT. AT THAT TIME I CALLED MINI AND TOLD THEM THAT MY RIGHT REAR LOWER CONTROL ARM WAS DAMAGED. I WAS TOLD BY THE SERVICE MANAGER AT MINI THAT MY DRIVING WAS THE CAUSE OF THIS AND THAT IT WOULDN'T BE COVERED UNDER WARRANTY. I THEN TOOK PICTURES OF THE LOWER CONTROL ARM WHILE IT WAS STILL ATTACHED TO MY CAR, THESE PICTURES SHOW THAT THERE WAS A SHEARING EFFECT ON THE REAR-MOST PART OF THE ARM AND THERE WAS NO BENDING ON THE ARM. I THEN HAD THE CAR TAKEN BY FLAT-BED TO MY MINI DEALERSHIP WHERE THEY ARE REPLACING THE LOWER AND UPPER CONTROL ARM. MY PICTURES REFUTE WHAT THEY ARE SAYING ABOUT THIS BEING A DRIVERS FAULT AND THEY ARE REFUSING TO WARRANTY THE WORK.*JB

1) GRINDING NOISE WAS HEARD FROM RIGHT REAR CORNER OF THE CAR WHILE BRAKING. 2) UPON INSPECTION, IT WAS FOUND THAT THE RIGHT REAR BRAKE PADS HAD WORN DOWN COMPLETELY ALTHOUGH THE LEFT REAR BRAKE PADS HAVE APPROXIMATELY 1/2 PAD REMAINING. I HAD THE VEHICLE TOWED TO THE NEAREST DEALER FOR WARRANTY SERVICE. 3) VEHICLE IS CURRENTLY AT GLOBAL IMPORTS MINI IN ATLANTA AWAITING INSPECTION BY A SPECIAL BMW ENGINEER TO DETERMINE THE CAUSE OF THIS UNUSUAL WEAR OF BRAKE COMPONENTS. THE BRAKE CALIPERS THAT OPERATE THE BRAKE SYSTEM ARE SUSPECTED TO BE DEFECTIVE/FAULTY. THIS SAME PROBLEM ALSO OCCURRED ON THIS SAME VEHICLE ON MAY 8, 2004. AT THAT TIME, THE VEHICLE WAS ALSO SENT TO GLOBAL IMPORTS IN ATLANTA WHERE THE BRAKE PADS AND ROTORS WERE REPLACED UNDER WARRANTY DUE TO EXCESSIVE WEAR FOR THE MILEAGE ON THE CAR. HOWEVER, THE BRAKE CALIPERS WERE NOT INSPECTED OR REPLACED BY GLOBAL IMPORTS AT THIS TIME. BECAUSE THIS HAS OCCURRED TWICE ON THE SAME VEHICLE, I DO NOT FEEL SAFE DRIVING MY VEHICLE WITH A SUSPECT BRAKE SYSTEM. THE SERVICE MANAGER AT GLOBAL IMPORTS (ERIC PETERS) HAS STATED THAT HE BELIEVES THIS TYPE OF INCONSISTENT UNEVEN BRAKE WEAR IS CONSIDERED "NORMAL" PHOTOGRAPHS TAKEN AT THE TIME OF RECENT OCCURRENCE ARE AVAILABLE TO SHOW A COMPARISON BETWEEN THE BRAKE PAD THICKNESS ON BOTH THE RIGHT AND LEFT SIDE OF THE VEHICLE. PLEASE CONTACT ME FOR THESE PHOTOGRAPHS. *NM

WHILE PULLING INTO THE PARKING GARAGE AT WORK, THE REAR OF MY MINI COOPER S MADE A NOISE. THE CONTROL ARM ON THE RIGHT, REAR SUSPENSION BROKE. WHEN LOOKING UNDER THE REAR, THE CONTROL ARM WAS IN TWO PIECES, BROKEN IN THE MIDDLE. THE VEHICLE IS AT THE DEALER AND I WILL BE REQUESTING THE PART BACK. *JB

COMPLETE FAILURE OF THE INTERNAL CONTROLLER AREA NETWORK, RESULTING IN BLOWN ELECTRONICS, SERVICE ENGINE SOON LIGHT, ABS LIGHT, DSC LIGHT AND AIR BAG LIGHT. CAUSE WAS APPARENTLY A FAULTY RADIO. HOWEVER, A REPLACEMENT RADIO FAILED WHEN INSTALLED IN THE VEHICLE, BRINGING MORE CONTROLLER AREA NETWORK PROBLEMS.*AK