I just had the top of my 05 cabrio S replaced by MINI (april 18, 2011) because of a known issue they are not admitting is a problem with a lot of the 05/06 cabrio S production run. A brake light cable on the driver side causes pressure on the top in the folded down position which eventually wears out the threads (mine only took 2 years, the tops that are 4 years old or older it's REALLY evident).

Look for the issue on the drivers side, about halfway back on the side, and 3 inches up. The area is about the size of a dime or smaller, but it's there if you look for it.

I have looked at other MINI's in parking lots and even at the dealership, and it's almost always there. I threatened the dealership with lititgation, and they finally replaced the top under "goodwill", because it was caused by mechanical defect of the car configuration.

This should be a recall, or they should fix it for free, and it affects a lot of owners.

 

I have a wear spot (soon to be a hole) in exactly the same spot on my 2005 with 30k miles. How hard did you have to push the dealer to get them to cover this under goodwill?

 

Pretty Hard. Originally the manage wouldn't do anything, and gave me an email with the regional tech's name blacked out, then gave me one accidentally with the name of the guy, Pete Peters, not blacked out. Trying to get the name of the Pete Peters was almost impossible, MINI wouldn't admit to his existance, so I started emailing Pete Peters and the area VP, the local owner of the dealership, and the manager at the dealership. I also got on tape (legal in VA, not DC or MD) the manager stating I "needed a new canvas and frame, not just a canvas, but there was nothing he could do."

The regional tech tried to tell me it was my fault, but when I threatened litigation, they sent the matter up the chain for a verdict on whether to do it or not, and the muckety-mucks said "Do it", so I got a new canvas and frame.

I think they KNOW this is their fault with a mechanical defect, but people aren't really noticing that it is happening. Now that mine has been fixed, the precedent has been set for anyone to have it fixed, and I'm more than happy to supply my paperwork to anyone going to court.

 

Congrats with the new top.

There's been other cabrio tops that have been replaced under warranty or courtesy. It really depends on the dealer.

 

If you're talking about the little area near the back, to side of the drivers and passengers seat windows, you'll find matching wear spots at the rear corners of the top, roughly above the tail lights. This is simply a result of the top being folded on itself and then rubbing as you drive over bumps, etc. Unless you can prevent the top from folding completely (not possible on the 1st gen), you're gonna get that wear no matter what. Mini replaced my top (an '06 JCW) and after a few months I noticed the same wear patterns appearing. With nothing else to do, I got myself some black felt fabric, doubled it over, and cut a square roughly 5" x 5". Thenk when I fold my top back, I stop just shy of fully down and slip the doubled over felt squares between the fold where the wear is happening. Since starting that procedure, I've not seen the wear get worse. Yes, it's a bit of a hassle, but hey, at least it seems to work.

Also, if there's no wind happening, the felt will sort of stick in place if you push it on the fabric top at the two rear wear areas and it will stay in place as you lower the top. I just open my trunk, grab the two squares where I stash them in the left corner, and slap them on. Then I get in the car, lower the top and go. Of course, I need to remember to retrive them when I put the top up. And if it's windy when you put the top up, put the top up only just a little bit and then retrive them. Otherwise you'll be chasing the felt down the road.

Finally, to make folding the top easier, you could get the remote programmed (possible?) or use one of those aftermarket controls. I've done neither and what I do when I need to be outside the car when folding it is this:

Key in ignitiona and turn on. (Don't start engine.)
Thumb both front windows down all the way.
Reach up and crack the top open an inch or so.
Then I reach around to the top button from the outside through the crack and continue putting the top down while standing next to the car. At no point do I actually get in the car.

Hope that helps.

 

Oh, I'm aware of the normal wear and tear expected on the top, and of the wear marks caused by the mechanical stuff addressed in SIB 540105, but this is BEYOND what the SIB covers. This is caused by the 3rd brake light wire rubbing the top in the folded down position on the drivers side causing the top to wear out prematurely. It is a design defect of the car wiring system, and therefor MINI should be held accountable and replace the tops that are wearing out due to their mistake... even if they are out of "warrantee".

 

Interesting. I've not observed any wear due to the wire back there but I'll now look for it. (I'm in northern California and the top is down every time I drive, even in the winter, unless it's actually raining.)

Also, can you direct me to a copy of SIB 540105?