My Fourth Windshield

Sections: Uncategorized Nov 17th, 2003 31 Comments

After almost 15 months and 20,000 miles my third windshield finally cracked this morning. Thank God for comprehensive glass coverage from State Farm – otherwise I'd probably have spent around $1200 just on windshields over the past 18 months.

As soon as I got in the car this afternoon I immediately noticed something in the lower portion of the passenger side near the right windshield wiper. Sure enough the crack looks to be the result of an impossibly small (almost pin hole is size) chip most likely from a stone. It's so small in fact that it took a flash light shining on the area to see the reflection of a very small chip.

Interestingly I've witnessed several large stones hit the windshield directly in the middle portions of the glass with no damage. It would seem that the MINIs, or at least the '02 and '03 cars, are particularly susceptible to cracks in the extreme lower and higher areas of the windshield.

According to this post from a couple months ago MINIUSA did find what they believe to be the culprit in regards to the stress fractures that were plaguing the earlier cars. How this will impact issues like mine where the crack is due to a incredibly small stone chip is what a lot of us are now asking. Is the issue simply the height and angle of the MINI's glass? Is it curve which makes it unusually suspectable?

So now the next step is which glass do I choose as a replacement. The old standard MINI windshield or the newer and rumored to be slightly thicker PPG glass. The downside with the PPG glass is that it's not an OEM product and there might be some fit and finish concerns. The up side is that it can't possibly be worse than the OEM glass in terms of cracking. Does anyone have experience with the PPG version?

Written By: MF Staff

D. Martin

I had a pin hole just below the drivers side wiper. Next morning I had a 6 inch crack running an inch above the bottom of the windshield.

I told Allstate that I wanted the PPG replacement.

No problems with installation at a local auto glass shop.

Only had the car for a couple months when I got the crack. It's been 5 months since with no problems.

I have a 2003 cooper, Dave
R. Hall

I had a stone hit the very middle of my windshield. It put a spider crack the size of a half dollar in it. So instead of paying the money before the harsh winter roads hit, I decided to get it repaired. I can hardly notice it is there.

I live in Rhode Island and insurance companys cannot offer winshield coverage on a vehicle in this state.

Bummer… I would have to pay my deductible before I even thought about getting some money from my insurance company and windshields don't cost more than $500.00.
Steve Rosenblum

When my windshield cracked in September, I had PPG glass installed by a local insurance company recommended place.

So far so good. Fit and finish are fine. The only downside is that you have one less MINI logo on your car :)
Ryan

I'm on my third windscreen right now. (my second PPG) The PPG glass is more economical for the insurance claims, which I think will help us keep our comprehensive premiums down in the long run. In my opinion, the quality is nearly identical. A month after getting the first PPG installed, it cracked from another highway stone traveler. But my current glass has been there for nearly 6 months and no problems. Like explained in the previous post, the only difference in the glass is the missing MINI logo. Everything else is the same.
http://www.dolch.net Matt Dolch

I've read the 2004 windshields are cracking too- check the threads on northamericanmotoring.com

… but, it does seem the frequency is significantly reduced. So I guess some improvement is better than none whatsoever…
Frank

2002 MINI Cooper CVT: 18,500 miles and still has original factory Sekurit-St. Gobain windshield glass. No problems.

2004 MINI Cooper S: 1,600+ miles and zero problems with the windshield.
http://lawrenceotoole.com Lawrence O'Toole

Just had my third installed yesterday. Warranty covered.

Seems I'm one of the lucky 02 owners experiencing “casual A-pillar flex” as both times the cracks were not caused by stone chips or other impacts.

Anyone know if the extended warranty covers windshields??? Looks like this might be a reoccurring problem…
Dave Bunting

My MINI went through 4 MINI windshields in a year. Then the PPG windshield became available so I had that installed. So far so good (6 months later and no cracks or chips).
Frank

It will be interesting to see if the cracked windshield problem happens more often on models with Sunroof vs those not so equipped from the factory.

Interestingly, neither one of my 2 MINIs have sunroofs.

I am not sure how the presence of the sunroof affects the entire roof/pillar structure but would be interesting to take a survey.

Perhaps it is all equal, who knows.
Kim

We've had a windshield replacement after a large stone ruined an afternoon of motoring. Question, has anyone experienced an increase in cabin noise after getting the windshield replaced? Our dashboard is having lots of noise, sounds like it's loose parts or something. We're going to take it back in again to get checked out by Knauz but I didn't know if anyone is experiencing this too?
Frank

Assuming that your new windshield was installed properly, there should not be any noises coming from the dashboard (Unless trim pieces needs to be removed and re-clipped as part of the installation). It is also a sign of a shoddy install the fact that you are getting wind noise. One of the most amazing things about the MINI's cockpit is the almost complete lack of cabin windnoise around the window seals.

You need to keep in mind that a badly installed windshield is not only an inconvenience but also a clear and present danger. Your front airbags relay on the integrity of the windshield install on the frame and pinch weld to properly work during deployment. There has been cases where the windshield popsout completely out of its frame during an accident because of improper installation.

Take back and have them rectified the entire installation. Typically you get a lifetime guarantee on the new glass and installation for as long as you own your vehicle.
Kim

Thanks Frank, I know it's a big problem and my husband and I are taking the car back to Knauz to get it fixed…just didn't know if anyone else had experienced any craftsmanship problems with the reinstallation of their windshields. It'll be the third time for just one windshield….what a shame.
David

My week old '04 MCS (no sunroof) just developed a crack. The crack started from the bottom right behind the middle of the wiper blade on passenger side. Over the course of an one day it moved up five inches then across horizontaly toward the drivers side… No rock or debris hit but but there is a approx. 1/32 inch hole about an inch up from the bottom of the crack. This to me was the result of the crack, not the cause. I could not see how a rock could get up to this position as it is virtually right behind the wiper blade. I will be taking this to my dealer on Monday. I actually bought the car in NY and live in CA so hope there will be no problems…. any advice from those with similar crack issues would be appreciated..
Jamie Koch

I see arepeative comment which I myself have experienced. A stress fracture (manufacturers defect I call it). The fracture seems to have a habitual pattern of starting near the passenger bottom of the windshield and spreading like crazy. When I confronted the BMW dealer I purchased my mini from they tried to play it off. I would not settle. I am very fair and any layman could tell this is a habitual problem. Shame on them. Well, not even 2 weeks later, a stone actually hits the windshield, and now I have another problem everyone seems to have. A crack that stars from the utmost area of my driverside windshield. My hypothesis, they need to manufacture a new windshield because the outer extremeties of the windshield are weak, and no dealer wants to DEAL with it. Shame, shame.
Hillary Cowan

I've had my car for 3 months today and 3,500 miles and I just got a mystery crack. It starts underneath my driver side windshield wiper goes up 4 inches and to the right 3 inches. I'm so bummed. This is my first new car and now it's elderly before its time. Now I know where my tax return is going. :(
Diana Bandt

2004 MINI S. My MINI is three months old. I found a large crack from the top center of the windshield down and around the rain sensor and heading off into passenger side like lightening first thing this morning. No apparent impact mark. Dealer told me this morning stress fractures are rare but if it is a stress fracture (he's only seen one ever)it will be covered under warranty. I had a star burst the first week I owned the car from a rock impact but this crack seems to have started on its own.
Erica Jamin

I have a 2004 Mini Cooper S, two months old. A crack developed in the windshield after about 5 weeks – started at the very top almost dead center (a little towards the driver side), and now had headed down about four inches and towards the passenger side about four inches. I'm taking it in next week to see if it's this mysterious “stress crack” – if they tell me it is not covered I will be so upset! This is obviously a manufacturer issue.
Chris

I had a stone hit the upper portion of the windshield on the passenger side between the a post and the rearview mirror. The chip was repaired by a glass company at my residence. Sekurit glass is very soft and speaking with a mechanic, he suggested that because of the slope of the windshield, it may be suseptible to damage. I have 15k on my Mini and the glass does have several pits. OEM suppliers for BMW group are Sekurit, sigla and Pilkington. I have always had good luck with Pilkington and Sekurit both except with the MINI
Richart

I live in Germany. I just got my 2005 Mini a week ago. When I returned from shopping, my entire passenger window was shattered. The German policeman said that sometimes the temperature causes some car windows to shatter like this. He said that a passerby called him when she saw the window shatter by itself. This sounds crazy to me. Is there such a thing? Nothing was taken from my car. I am just so disappointed.
Linda

I am in the auto glass business; since I have not seen a Mini with a windshield problem, I must rely on what I am reading. (Please, someone infomr me if I have this incorrect) I believe I am hearing problems with mysterious cracks, edge cracking, repeated breakage of the windshields and the manufacturer warrenty picking up the costs of some of these windshields? If this is true; it sounds like you all may be dealing with stress cracks resulting from a structural problem with the vehicles. I would ike to offer this suggestion to each of you; report the breakages to the National Highway and Traffic Safety Administration. Your windshield is an integral part of the vehicle's safety mechanisms. If indeed, the breakage is a result of a structural defect, these cars should be recalled before one of you is involved in a major accident, one in which your windshield performance (or in this case – non-performance) could be fatal. I am not condemning your vehicles, I am merely relaying what I relay to hundreds of people weekly; you windshield is your safety net if you have an accident. Repair the chips and cracks immediately. (Yes, I do replace them also) If I were to see you as individual customers, I may never think that there could be a structural problem, especially since I see some claims of rock chips causing the damage; but to read these complaints as a collection, it is easy to see that there is more to the problem than “bad” glass. I wish you all luck with your vehicles; but please, report the problem to the proper industry so that a follow-up will be conducted.
ted

I think you should look into a forced buyback from the MINI manufacturer. I am in the middle of arbitration/lawsuit forcing Chevrolet to buy back a 2004 Aveo because of bad windshields. Next week is number four. Missouri has a Lemon Law which basically says four attempts to fix and the carmaker buys car or gives you a replacement. The problem really is that when a windshield is replaced it may be unsafe in a crash and pop out, thereby making the passenger side air bag ineffectual. Also if the car rolls over the poorly installed windshield pops out and the roof crushes your head or breaks your neck. Windshields must be installed properly or you risk death or disability in a wreck, even with airbags.
http://na Heather

We, too are having a problem with our 2004 MINI’s windshield. Just after we got it, we were hit by a small rock and it chipped the windshield. We’ve had it for a year or so, now. This morning my husband called me on his way to work to tell me his winshield was cracking before his eyes. Just under the driver side windshield wiper there is a tiny hole. It extends down into the moulding and out of site. It extends upward about eight inches, and over to the right about two inches (so far). This is less than twelve hours time! We’ll have it replaced, but not before I give someone an earfull. I have to at least try to get some help with replacement, especially if I’ll have to replace it several more times. That’s unacceptable.
DavidKC

I just found a similar windshield crack on my MCS. Per one of the posted suggestion, we all should file a complaint to National Highway Traffic and Safety Administration, http://www-odi.nhtsa.dot.gov/cars/problems/complain/results.cfm. Hopefully, enough complaints will trigger a defect investigation. Someone has started a complaints (3x) and I will be next.
Mike

Much like everyone else on this page, I have had the windshield of my 2003 CooperS crack from a small rock. It started below the drivers wiper and moved up 6-7 inches and then went to the right 24 inches and then up another 8 inches. The impact of the rock is almost invisible to the eye. You need a bright light to highlight the impact position. That is just what the dealer did to show that it was not a manufacturer fault, but a mother nature problem. I am in the Army and stationed in Alabama, where there is no glass clause with my insurance company. Of course the windsheild was $497.00 and my deductable is $500. What a coincidence. It will be replaced on thursday. I see alot of mentions of a glass refered to as PPG. Can anyone tell me what the initials stand for? Thanks.
http://www.tinnitus.org THC staff

My second windshield in 1 year from new!

BMW 320i. The first glass cracked in low temperatures without a stone chip. Replaced free under warranty. The seond time (also when in extreme cold) there was a small stone chip with crack pattern exactly as described by MF Staff et al. Autoglass replacer said this was a common problem. Laminated windshields are designed to provide approx 30% of the cars stiffness, therefore they take a lot of stress, rather than just being a window. The area around the edge (black) is where the glue is and where maximum stress occurs. The common scenario is that a tiny stone chip is created in this area. No need to hear it. This then allows air between the laminas. Later, often with sudden temperature change (very cold, applying hot water or demister to windshield) the laminas seperate futher causing a vertical then horizontal crack to appear. Take out whatever insurance you can, but accept that replacing laminated windshields in modern cars is part of the running expensenses!
Bob

I have a 2004 MCS with almost 50k miles. I will soon be installing my fourth windshield in it. The first one cracked from a small stone chip (barely visible) that started just below the passenger side wiper. My second windshield only 3 weeks old hit by another small stone, cracked in the upper corner in front of the passenger. The third lasted about 9 months before cracking in the same vicinity as the second from another stone. All replacements have been done at the dealership, I don’t beleive they use PPG glass. Has anyone had any problems with the PPG glass?.

I have driven the same route with many different vehicles for the past 10 years and have not had any other windshields crack as easily as the one in mymini. There must be a problem with the design of this window that promotes this damage.

I am going to look into the PPG glass, maybe it will solve the problem.
John Futch

I just found a stress crack in my ’05 Aveo windshield. I’ve had it less than a week. The dealer says it was caused by a rock. There is a tiny super tiny knick in the glass but theres no way this thing was caused by a rock on the interstate. The crack started from underneath my rubber stripping.

Im 23, never had to deal with something like this. Please email me any suggestions. The dealer says they won’t replace the windshield. I feel like I am being railroaded.
Eric Borneman

We are on our second windshield, about to be on the third, from a rock chip so small that a mosquito would have survived being hit by it, and the crack develops across the whole windscreen, both times near the bottom. Mini USA could care less, and I am disgusted. You can’t even see the chip, you have to feel for it with a fingernail..both times. I’ve been hit by small boulders in my other cars from cement trucks at 75mph and never had a windscreen crack. I’m writing to the CEO now. I’ve had it.
Winnie Tang

I would be interested in knowing what people’s experiences have been when they contact minicooper regarding possible defective windshields.

I replaced one windshield two months ago and now have two more holes in my windshield. It apears that just a single, small pebble hitting the mini cooper’s windshield will cause holes & cracks. I haven’t experienced anything like this in my other cars. The minicooper windshield seems so fragile.
http://www.advantageautoglassrepair.com/ Windshield Replacement Toronto

A larger crack and the crack will affect the windshield to a point where it is not considered safe, and you will have to replace the windshield entirely.
http://www.unityautoglass.ca/ Toronto Windshield Repair

To check on the severity of the cracks and keep them from worsening. In the hot weather, it is advised to make a crack on the windshield.

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