Three problems related to steering rack and pinion have been reported for the 2004 Mini Cooper. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2004 Mini Cooper based on all problems reported for the 2004 Cooper.
My power steering failed. Cause unconfirmed as yet, but this apparently is a known problem. Power steering started again when I restarted the car, but now the pump motor (or perhaps the fan) won't shut off and there is no fuse to disable. Must disconnect the battery to shut it off and avoid draining the battery. Steering did not lock up, but very difficult to overcome the rack-and-pinion steering linkage resistance.
My 2004 Mini experienced intermittent steering problems in Feb. Of 2011. Steering became difficult at times and then nearly all the time. Got new power steering pump. Mostly fixed but felt odd at times. Steering became permanently difficult in June 2011 and had pump replaced but didn't fix the problem. Advised to replace rack and pinion. Plan to do so. Steering bills at about $2,000.
The contact owns a 2004 Mini Cooper. The contact was driving 70 mph when the power steering malfunctioned and the vehicle became difficult to control. The contact stated that the power steering pump was replaced several years ago by a local mechanic. The vehicle was taken back to the local mechanic for the most recent failure for a replacement to the power steering pump and the rack and pinion. The contact stated the vehicle was unsafe to drive and was concerned with the possibility of the failure causing a crash. The failure mileage was 96,000. Updated 06/24/11 updated 06/30/11.