Most common 2004 Mini Cooper S problems
Share of the 247 complaints; one complaint can involve more than one system. "~" is the median mileage when the problem started.
Mini Cooper S complaints by model year
Best Cooper S years: 2017, 2016, 2021. Years to avoid: 2005, 2007, 2004, 2006, 2003. Compare all years →
2004 Mini Cooper S recalls (2)
Steering › Electric power assist system
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.
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.
Tires › Pressure monitoring and regulating systems
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.
Remedy: 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.
NHTSA defect investigations
Federal safety investigators have looked into 2 possible defects involving the 2004 Mini Cooper S:
Loss 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…
Loss 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,…
What 2004 Mini Cooper S owners say
Steering all 210 →
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.
I was driving my Mini Cooper s on the freeway going into a turn, the wheel became extremely hard to turn with no notice. I could not make the turn all the way and the drivers side tires and fender hit the curb on the freeway. I fought the car off the freeway and let it sit for 15 mins while I called Mini. The dealer said that my power steering had failed. After a wait of 15 mins the car started and drove just fine. I drove the car to the dealership and they tested the power steering pump and said that it was good at that time. They told me that it would continue to be a problem with just giving out at random times unless I spent $4000 and had all the components replaced even though it tested good at the time. They replaced all the bushings and struts in the front at that time for $2000. They told me not to replace the power steering unless it totally stopped working. …
Electrical system
On my way up driveway I noticed a sharp stinging sensation in the lumbar of my back. Felt sort of like an "continuous electric shock". I immediately arched my back as a reaction to the sting and had to straighten my back in order to control the vehicle. When straightening my back I felt something hot, very hot this time like something that was on fire. I could not longer control the vehicle grabbed for the handle opened the door and rolled out onto the driveway while the vehicle was moving. The vehicle bucked and stalled out. I immediately looked at the vehicle interior and noticed that the seat was smoldering and there was a hole the size of a quarter burned through the seat in the lumbar. It was a 100 degree day so I wasn't using the seat heater, nonetheless it was on, malfunctioned, caused a fire which resulted in me jumping out of the moving vehicle. …
I was driving my daughter to school when it first happened, the wheel got so tight and I hit the curb. Thank god I was in a school zone and therefore I was driving slow. After that, I noticed that same day that my battery was drained when I was leaving from work. I got a jump but then it happened again when I stopped for groceries. I figured something must be wrong with the battery (which is fairly new) or the alternator. I took my car to a shop and they diagnosed the battery and the alternator was fine. But they also said there was a strange noise coming from my power steering pump. I bought power steering fluid thinking that was the reason, but after I poured some its still the same. I started researching and I found out a lot of people are having this same issue and its a defective issue for this Mini generation.
Windows, wipers & sunroof
My 2004 Mini Cooper 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 Mini owner in ma who has now had 6 windshields replaced since purchase. The Mini community 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. …
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 Mini Cooper 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 Mini coopers, 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. …
2004 Mini Cooper S engines & fuel economy
| Engine | Transmission | Drive | MPG city / hwy / combined |
|---|---|---|---|
| 1.6L 4-cyl supercharged | 6-speed manual | FWD | 22 / 31 / 25 |
EPA ratings. Class: Subcompact car.
Frequently asked questions
Is the 2004 Mini Cooper S a good car?
Based on 247 owner complaints filed with NHTSA, the 2004 Cooper S rates avoid: 4.9× as many complaints as a typical year of the Cooper S at the same age. It is one of the Cooper S years we suggest avoiding. Complaint counts don't account for sales volume or individual maintenance, so have any used car inspected before buying.
What is the most common problem with the 2004 Mini Cooper S?
The steering — 210 complaints, 85% of all complaints for this model year, most often about hydraulic power assist › pump. Next are the electrical system (19) and windows, wipers & sunroof (12).
How many recalls does the 2004 Mini Cooper S have?
There are 2 recalls for the 2004 Mini Cooper S, the most recent from October 15, 2015 (electric power assist system). Recall repairs are free at any authorized dealer — check whether yours has been done with the VIN recall check.
What are the best and worst years of the Mini Cooper S?
The best years by complaints, compared at the same age, are 2017, 2016 and 2021. Years to avoid or approach with caution: 2005, 2007, 2004, 2006 and 2003. See the full Mini Cooper S years comparison.
At what mileage do 2004 Mini Cooper S problems happen?
The median mileage reported in complaints is about 74,000 miles; 20% of problems with a recorded mileage started before 50,000 miles.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.