What 38 owners told NHTSA about the 2016 Mini Cooper Hardtop

Rear passenger tail light casing/bucket had burnt connections. Replaced casing/bucket and bulb. Worked for short time, tail light failed a second time. Casing/bucket & bulb replaced, again worked for short time and then went out. Took vehicle to another mechanic after passenger side headlight failed. New mechanic checked casings/bucket - connections looked okay, however both wiring harnesses were severely burnt. Headlight harness was all bare wires. Mechanic unable to determine cause of the severe heat that would lead to both the headlight & taillight wiring harnesses becoming burnt so severely. Mechanic was concerned of the potential for this issue to cause vehicle fire. Suggested to follow up with dealership to have lights & wiring harnesses on Driver side checked After research online regarding this year/make/model - I have found numerous other reports of other owners experiencing the same issues with burned wiring harnesses causing both front and rear light failure with no known causes.

NHTSA ODI 11605757

* Component/ system that has malfunctioned and failed - The Driver side tail light circuit board and pig tail malfunctioned. The connector has corroded and the plastic plug housing looks melted on the earth / brown wire. This in return damages the the ground connection for the tail light rendering the turn signal the reverse light and the brake light inoperable on the effected side. YES, MY VEHICLE IS AVAILABLE FOR INSPECTION AT ANY TIME. *A driver behind an affected vehicle could be confused which could increase the risk of a crash. *The vehicle has been inspected by a licensed MINI Dealership. They failed to report two of the three nonworking rear lights that have failed due to the connector becoming corroded. The corroded plastic plug housing becomes melted on the earth / brown wire. This in return damages the the ground connection for the tail light rendering the turn signal and brake light inoperable on the effected side. In this case it is the rear driver side. *There was/ is no warning until long after the first second and/ or third rear light(S) were not operable. Intermittently (sometimes) a warning will popup when turning on the vehicle. The vehicle will not warn the driver about and and / or all three lights each and every time the vehicle is turned on. ALSO while the vehicle is in drive or in reverse , the driver will not have any warning what so ever that the three lights 1. The driver side rear break light 2. The driver side rear reverse light 3. The driver side rear turn signal are not working due to a malfunction. * note that there is a very strong burnt/melted smell that comes from the connector as well. I could smell it on my fingers after removing the connector so I could check the rear bulbs for replacement. Please note the 1st photo-this is how the dealership left my connector after their assessment. Additional photos are of the connector/ pig tail/ circuit board corrosion. Intermittent warrnings for some of the nonworking lights.

NHTSA ODI 11569727

There is a design issue resulting in failure of the connector for the rear tail light assembly. The connector corrodes and the plastic plug housing melts. This damages the ground connection for the tail light rendering the turn signal and brake light inoperable on the effected side. This has happened on the right rear of our Mini Cooper JCW hardtop. Searching on the web shows this to be a common problem for the F55, F56 & F57 MINIs. As this failure makes the car brake light system non-compliant with FMVSS lighting requirements, there should be a recall to address this issue.

NHTSA ODI 11562935

Rear tail lights have a bulb socket and a 6-pin connector that have a tendency to burn at the brown ground wire where the connector and bulb socket meet. Requiring replacement of both parts and disabling the rear tail light (brake, turn, and reverse lights). It requires rewiring the 6-pin connector and replacing the bulb socket. About $60 in parts. When this occurs it an alert comes on the dash of a malfunction to all three rear lighting functions. One or all three of the lights can be affected. However, due to the complexity of the parts and labor required, it can be burdensome for people to diagnose and then afford to repair, if they don’t know how to repair themselves. Web searches helped me diagnose the issue and find the burnt connections on our vehicle, with folks commenting of a known issue on MINIs and BMWs for this type of connection, surprised it hasn’t been part of a recall. An example can be found here: https://www.mini2.com/threads/solution-driver-side-tail-light-failure-melted-connector.361711/

NHTSA ODI 11516815

Tail light assembly including brake light and turn signal failed due to burnt electrical socket and connector. This is caused by a faulty grounding point that is very clearly a manufacturing issue but wasn't considered as a recall for some odd reason. This issue is prominent in several BMW 3,4, and 5 series models

NHTSA ODI 11509134

Left side headlight has needed to be replaced three different times at a cost of $1400 each time.

NHTSA ODI 11467068

REAR LIGHT CONNECTOR OVER HEATING, MELTING AND SHORTING.

NHTSA ODI 11361203

REAR BRAKE LIGHTS..IT COMES WITH 3 SMALL BRAKE LIGHTS ...TWO ON BUMPER & ONE ON TOP SCOOP, ALL RELATIVELY SMALL. THE MAIN TWO ARE MUCH BIGGER BUT ARE ONLY USED FOR DRIVING LIGHTS & TURN SIGNAL. 'IT MAKES NO SENSE '. THIS NEEDS TO BE CORRECTED, RIGHT ?

NHTSA ODI 11090194

PLEASE CHECK THE REAR BRAKE LIGHT PHOTOS (HALFWAY DOWN, THIS PAGE: HTTP://WWW.NORTHAMERICANMOTORING.COM/FORUMS/R55-CLUBMAN-TALK-2008/293675-2016-CLUBMAN-13.HTML). I WAS FOLLOWING ONE OF THESE CARS THE OTHER DAY AND IN STOP-AND-GO TRAFFIC THE LOWER BRAKE LIGHTS ARE SIMPLY NOT VISIBLE! THE LARGE (TURN SIGNAL) LIGHTS JUST BELOW THE REAR WINDOW "LOOK" THEY'RE SUPPOSED TO BE BRAKE LIGHTS BUT, OBVIOUSLY, DON'T COME ON WITH BRAKING. NO QUESTION, THIS WILL RESULT IN COLLISIONS, SOME SERIOUS. NHTSA NEEDS TO BE PROACTIVE AND FORCE A CORRECTIVE REPAIR; THIS IS TRULY A PUBLIC HEALTH.SAFETY ISSUE!!!

NHTSA ODI 10882328

THIS CAR HAS TERRIBLY PLACED TAILLIGHTS. THE LIGHTS ARE NOT PLACED IN A VISIBLE LINE OF SIGHT. THE MINI CLUBMAN I SAW HAD VERY SMALL LIGHTS BELOW THE LARGE LIGHTS ON THE REAR DOORS. THESE VEHICLES SHOULD BE RECALLED AND THE LARGE LIGHTS THAT APPEAR TO BE TAILLIGHTS SHOULD BE MADE FUNCTIONAL. THE TAILLIGHTS ON THIS VEHICLE ARE WHAT APPEAR TO BE REAR FOG LIGHTS AT THE VERY BOTTOM OF THE CAR. THIS IS AN AWFUL SAFETY ISSUE AS YOU CANNOT SEE THE LIGHTS IN TRAFFIC. I'M SURPRISED THERE HAVEN'T BEEN SEVERAL ADDITIONAL COMPLAINTS.

NHTSA ODI 10824831

SPOTTED NEW CLUBMAN IN FRONT OF ME ON HIGHWAY. VEHICLE CAME TO STOP ABRUPTLY WITHOUT APPARENT WARNING. THANKFULLY I WAS PAYING ATTENTION. APPARENTLY TAILLIGHTS ARE NOT THE LARGE LIGHTS ON THE TRUNK, BUT THESE SMALL LIGHTS PLACED DIRECTLY AT THE BOTTOM OF THE REAR END, ALMOST INVISIBLE IN STOP/GO TRAFFIC. I WAS UNDER THE IMPRESSION TAILLIGHTS HAD TO BE PLACED HIGHER UP AND WOULD HAVE BEEN THE LARGE LIGHTS ACROSS THE ENTIRE REAR SECTION OF THE CAR, BUT THAT WAS NOT THE CASE WITH THIS CAR. I CAN SEE THIS MODEL OF CAR GETTING REAR ENDED QUITE FREQUENTLY WHEN PEOPLE UNEXPECTEDLY MISS THE TERRIBLY PLACED LIGHTS AT THE BOTTOM OF THE CAR. THE LARGE LIGHTS YOU EXPECT TO BE BRAKE LIGHTS ACTUALLY ARE USED AS TURN SIGNALS ACCORDING TO ONLINE RESEARCH. I HAVE NO IDEA WHAT GENIUS DEVELOPED THIS AWFUL IDEA, BUT IT IS EXTREMELY DANGEROUS IN STOP AND GO TRAFFIC WHICH PLAGUES OUR HIGHWAYS. I DON'T THINK THIS SHOULD EVEN BE ALLOWED TO PASS FMVS.

NHTSA ODI 10824138