Huge win for car owners! All TSBs to be made public. The Center for Auto Safety just made the NHTSA (US Government) make public the full text of all TSBs from now on. They are the same organization that has petitioned the NHTSA & filed lawsuits to protect car owners over exploding gas tanks & other major safety issues. Whenever you drive in your car, you are safer thanks in part to a lot of work over the years by this small but very effective consumer advocacy group.

Please take a moment & say thank you by donating $5 or whatever you can to the Center for Auto Safety. Notes: Power steering problems are a major issue with the 2004 Mini Cooper, with hundreds of owners reporting complaints to the NHTSA about their power steering suddenly failing while driving.

Some power steering failures have caused crashes & injuries. Average mileage at failure is well under 100,000 miles & the repair cost is over $1,000. Not good.


fairly significant
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
11,691 miles

About These NHTSA Complaints:

This data is from the NHTSA — the US gov't agency tasked with vehicle safety. Complaints are spread across multiple & redundant categories, & are not organized by problem.

So how do you find out what problems are occurring? For this NHTSA complaint data, the only way is to read through the comments below. Any duplicates or errors? It's not us.

2004 Mini Cooper windows / windshield problems

windows / windshield problem

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2004 Mini Cooper Owner Comments

problem #11

Jul 312006

Cooper 4-cyl

  • Manual transmission
  • 43,000 miles


My 2004 MINICooper S has incurred two cracked windshields over the past two years, requiring the entire windshield to be replaced. Each crack occurred while driving after a small pebble nicked the windshield. After driving for nearly twenty years I find this rate of occurrence to be unacceptable. Although the angle of the windshield may be at a steeper grade than most vehicles, MINIhas failed to recognize solutions such as a stronger thicker windshield. A resolution is needed to prevent fellow MINIowners from purchasing replacement windshields on an annual basis.

- Pikesville, MD, USA

problem #10

Nov 012004

Cooper 4-cyl

  • Manual transmission
  • 26,000 miles
: the contact stated the windshield has been replaced three times within 1 year of purchase. On May 24, 2006, while driving a small object struck the windshield causing a crack which caused the fourth windshield replacement. The contact expressed that something must be wrong with the vehicle to make the windshield crack so easily. The dealership and manufacturer were alerted and determined the cracks were due to the impact of the object.

- Greenville, RI, USA

problem #9

May 102006

Cooper 4-cyl

  • Manual transmission
  • 20,105 miles
My 2004 MINICooper S, delivered in June of '04, having @ 20,000 miles on the odometer, is now on its third windshield all due to stress cracks. The cracks seem to be related to thermal instability. I.e. cold outside/hot inside etc. I personally know of one 2003 MINIowner in MA who has now had 6 windshields replaced since purchase. The MINIcommunity has determined that aftermarket us made glass by ppg does not have the propensity for such failures. I am reluctant to continue going to my dealer as this problem appears to be related to the foreign manufactured oem glass. On the other hand I should not have to replace the windshield with a non oem product, out of pocket to resolve the issue. For much more information, you can refer to the MINIcooper owners internet web forum "" the defect is wide spread from the MINIs introduction in '02 continuing through to '05 production models. To find this information, go to "beneath the bonnet" and use the search function in the upper right corner for "cracked glass". your assistance would be greatly appreciated. Feel free to call me if I can be of help. Sincerely, mark williams cfp

- Newport, RI, USA

problem #8

May 172005

Cooper 4-cyl

  • Manual transmission
  • miles


My 2004 MINICooper S had been parked, untouched, in my driveway for 2 days. I got in it last night and first thing I noticed was a verticla crack in the windshield extending from the top chrome molding 14" down, parallel to and 5" from the driver's side edge of the windshield. The local dealer said that MINIhad a problem with windshield breakage in the past "but not now". at his suggestion, I ran the tip of a ball-point pen along the crack and found a "chip" at the top of the crack. This "chip" is smaller than the tip of the ball-point pen. I've had many new and used cars and this is the first case where such an insignificant "chip" has propagated to a total failure requiring replacement without even being visible first.

- Saint Louis, MO, USA

problem #7

Apr 032005

Cooper 4-cyl

  • Manual transmission
  • 17,500 miles
Cracked windshield on a MINICrack extends from right edge and goes towards center and then turns up towards roof - crack about 12" long. No stone chip anywhere along crack.

- Hockessin, DE, USA

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problem #6

Mar 012005

Cooper 4-cyl

  • Manual transmission
  • miles
The windshield in the consumer's 2004 MINICooper cracked about 4 inches to the left of the VIN number. The crack started at the edge and moved up to the right. The dealer stated it was a stress crack.

- Woodstock, GA, USA

problem #5

Mar 092005

Cooper 4-cyl

  • Manual transmission
  • 850 miles


While driving normally a very very small pebble size stone hits underneath the windshield wiper on the passenger's side. The windshield immideiatly spiders all over the window. I've been told all the problems with the BMW windshields were corrected, but I've heard from over 20 fellow MINIowners of random cracking and failures within the first 2000 miles!!! this is totally unacceptable, and it isnt covered under warranty becuase it was the result of an impact.

- Chardon, OH, USA

problem #4

Mar 052005

Cooper 4-cyl

  • Manual transmission
  • 5,900 miles
On March 5, 2005, a 2 inch X 2 inch L shaped crack was first developed at the mid bottom section of the windshield of my 2004 MINICooper S. the short arm of the L originated from the bottom of the windshield. On the next day, after parking inside my garage overnight, the long arm of the L propagated another 2 inches. Today, while driving, the crack further extended another 1/4 inch. The problem is that the crack started with no obvious reasons. The only sensible explanation is due to design of the body struture or defect from MINIcoopers, and subsequently causes stress to the windshield. It does not take long to learn from the internet message board that many similar complaints or recurring incidents were also reported. One of the message board participant who installs windshield for car suggested us to file a complaint at this site because windshield problem can be fatal because of the followings: 1. act as a support for the roof. 2. act as a barrier to prevent passenger from ejecting of the car.. cause airbag malfunctioned. I strongly urge the NHTSA to investigate this problem immediately.

- Saratoga, CA, USA

problem #3

Jul 242004

Cooper 4-cyl

  • Manual transmission
  • 11,750 miles
First occasion - windsheild cracked adjacent to VIN # location. Seperated from vehicle body. Dealership replaced but took 5 to 6 weeks. Excuse was supplier changed. Second occasion - rock chip on intersate. Result. Surface chip and laminant crack (1/4" to 1/2" long). Have not replaced windshield. Watching for any progression in size. I've owned other vehicles that had rocks and such collide with the windshield, but none that cracked so easily.

- Lakeland, FL, USA

problem #2

Apr 132004

Cooper 4-cyl

  • Manual transmission
  • miles
Our minicoopers, 2004, received a very small chip. The next morning half of our windshield cracked from this chip. My husband spoke with steve, a MINIrep in houston, and was told the windshield had be recalled due to large amounts of stress on the windshield. He told steve that is exactly what has happened because the chip is so small located at the base of the windshield. We were told with the chip that the warrenty was voided. We would have to pay to replace the windshield. Steve went on to tell of 5 differrent stories of MINIowners having to replace their windshield in the last two months. If you look at MINIchat rooms, it is filled with many people having to replace their windshield, sometimes multiply times. It just does not seem right. So many windshield cracking due to rock chips. We would have had the chip treated, if it weren't so small, so a crack would not have happened, but there was no time, it cracked overnight.

- Missouri City, TX, USA

problem #1

Mar 182004

Cooper 4-cyl

  • Manual transmission
  • 3,500 miles
04 MINICooper S had a crack in windshield of unknown origin (probably stress). Had fixed 2 weeks ago under warrantly. New crack has developed already. In the process of resolving current defect. These vehicles have a design flaw. You guys need to add MINIto the list of your cars. I am going to select BMW because bwm owns MINI

- Bellevue, NE, USA

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