NHTSA Complaint #11455359 — 2012 MINI COOPER

The failed component is the "Footwell Relay Module" (FRM) which enables communication between the instrument panel in the passenger compartment and the engine control components in the engine compartment. When this component fails the following essential controls become inoperable: emergency flashers, turn signals, door locks, and windows. Most other "convenience features controlled by the car instrument panel become inoperable as well. This problem was confirmed by an independent technician, a technician at Mini of Stevens Creek in San Jose, CA, and the owner. No inspections of the part were ever done and the FRM failed without warning. This is a common failure in Minis due to a faulty design. The part is insufficiently protected from inrush current surge when a fully-charged battery is reconnected following service. It is also not sufficiently protected from induced voltage surges from EMI such as C, K or Ka band radar or electrical storms. One or more integrated circuits in the part are destroyed when exposed to current or voltage spikes rendering the part inoperable. The cost to replace the FRM (parts & labor) exceeds $1000.