I need advise please. This concerns the ongoing problems that MCS’s seem to suffer from with clutches, specifically the squealing noise most prevalent when starting out in 1st gear when cold. I have done numerous searches on NAM and Mini2 and have reached certain conclusions:
1. The problem has not yet been fixed by a redesign of the clutch system
2. By sticking with the OEM Dual Mass Flywheel and clutch kit there are NO guarantees of how long it will take for the noise to return, there seems to be no fixed pattern except that in most cases it is low milage. Many owners have had multiple replacements without success
3. There still seems to be no consensus as to the actual cause
4. Quite a few people have gone aftermarket to get rid of the unpredictable OEM clutch

I have a 2004 JCW MCS (running a 3% GTT lightweight crank pulley) with only 21000 miles on it, been having the noise for quite a while and it is becoming worse. I do not slip the clutch, it cannot be clutch wear. I have been driving stick on many different cars over thousands of miles and never had this sort of problem.

Now to the questions:

1. Can anyone please categorically state what exactly is causing this problem. These are the culprits most often identified:
A The throw-out (release bearing
B Glazing of the DMF surface (and these flywheels cannot be reworked
C The DMF itself (caused by the movement between the primary and secondary parts

2. If I continue to ignore it, what is going to fail and how catastrophically

If the flywheel and clutch itself were still OK (not worn) then it would be cheap to replace the bearing (except for the major work to remove the tranny). But that also means the bearing is of bad design or manufacture. What are the recommendations, obviously I am out of warranty:

1 Replace with the OEM setup and continue waiting in suspense to hear the noise again. This can become a very costly hobby!
2 Do I go with aftermarket and if so which is the best. I do not want to trade the squeal noise for a chatter/rattling noise which seems to be a consequence of a lightweight flywheel. I see a lot of talk about stages, would a stage 1 be the best solution/compromise, closest to OEM in terms of take-up and not too noisy? Car is for road use only

3 Do aftermarket clutches affect engine or tranny life negatively?

4 Is it a problem to run a lightweight CP and flywheel

Thanks. There is such a wealth of knowledge on this forum so please share!!

 

I for one don't understand why so many people feel the need to rush out and get this addressed. Other than a slight chubaca sound when cold or possibly wet the clutch functions just fine and from reading through multiple posts has not seemed to fail because of the sound.

My clutch does this a little and I will run it buy Waylen next time I see him but as long as my clutch works for another 50,000 miles i am not too concerned about it. If it were to make this sound more than just on cold damp days and more than just the first few miles then I guess I would be more concerned.

 

Ditto. My just started this a couple thousand miles ago (at aprox 22K) and I have a buddy with the same issue. He took it to his mechanic and was told the clutch is fine other than the "glazing" issue. No need to replace and it's just occasional when cold.

 

My car did it for 20,000 miles and then the sound went away and never came back. I have 13,000 miles with no squeal.

 

I see why Bluemax is worried I had the same problem on my 2004 S and Mini of charleston said they would eat the labor if I bought a new set up. Well I had it replacedwith a touch above stock and then it did it worse. No big problem it just makes your ride sound like junk. If you do get it replaced have Mini do the factory parts this way it will be warranted and get replaced if it still makes the noise.

 

Only happens on my 60,000 mile 04 MCS once or twice a week first thing in the morning when first fired up in the morning. Clutch feels and sounds fine the remainder of the day and after work. It's a "quirk" I've learned to accept...