Our Mini is still at the dealer. I will not be letting the dealer do the work because they said no warranty on clutch, so they will not tear it down. I was driving it when the clutch went out. I shifted into 3rd gear, there was a sound like something broke and then no I coasted to a stop. No forward or reverse movement after that.

 

that sounds very clearly like something broke. when you say no forward or reverse you mean with the engine running you can just shift gears with no resistance and no clutch?

 

Correct, there is no clutch engagement.

 

its very strange, most things that would fail like the shift fork would leave the clutch permanently engaged. Even a seriously worn out clutch disk would have a little drag to it.

Are you sure it isn't a linkage failure?

 

I never had a chance to look it over as it went from the side of the road to the dealer. The dealer said it needs a new clutch, but did not take it apart. The dealer we bought it from in July has agreed to buy the parts and as of now I plan to do the work. But I will do a complete inspection.

 

Here is some good background information on your year and model clutch and flywheel, along with an explanation of the dual mass and an application guide.

Please take a look and let us know if you have any questions!

Plus, welcome to NAM and please post some pix.

http://new.minimania.com/Search_Resu...clutch/default

Drive Hard. Drive Safe. Keep Grinning.

 

Good info, thanks. The dealer we bought it from has agreed to buy the parts and looks like I will do the install.

 

Thank you everyone for the input and discussion. It has helped immensely in the research.

Still no final desicions on one yet, but everything is helping.

 

I got our MINI home yesterday. The dealer had it for 9 weeks for the thermostat replacement. They paid for the rental car though. I thought I would replace the clutch myself. I had watched the video of the guy that did a write up and thought I could do it, but the All4 is a different animal. The rear drive shaft and complete exhaust from the down tube has to be removed and the front end and subframe have to come off which is a big job. So I am having an independent shop do it for me. Ended up getting a Valeo clutch kit and a Sachs DM flywheel.

 

Please keep us posted as to how it all works out!

Drive Hard. Drive Safe. Keep Grinning.

 

Decided to do the job myself this afternoon. I am 5 hours into it and didn't have big enough wrenches to remove the front driveshaft nut at the transfer case and no place open to buy them. Once the driveshaft is off I am probably an hour from having the transmission on the ground. Here are a few pictures showing where I am with the tear down. The red straps will hold the front end up when I drop the sub-frame.

 

All finished replacing the clutch. That was a big job with no reference material for the All4. The driveshaft removal was a pain in the ****. Then the transfer box has to be detached to get to a bell housing bolt, but can't be removed until the transmission is pulled away from the engine. It all went back together in about half the time it took to get apart. Surprisingly, the transmission went back on the engine first try.

 

Did something break or was it just the worn clutch disk?

 

The prior owner probably couldn't drive a standard very good. The clutch plate wears down to a point where the fiber material comes off leaving the metal to metal contact and no grip. That was my total failure I experienced.

 

Wow, great job! You turned that around really fast. I am assuming you are up to speed on how much fluid is required. Here's an application guide if you would like some backup:

http://new.minimania.com/Search_Resu...on%20fluid/All

Drive Hard. Drive Safe. Keep Grinning.

 

Well I am slightly glad I didn't buy the new clutch assembly yet. Unfortunately my baby was totaled due to a fresh on the road driver crushing the left front end while she was parked.

Had to switch to a family friendly vehicle(sedan) for the time being.

Sad sad day for T-Rexy

 

Oh my gosh! So sorry to hear that.

Drive Hard. Drive Safe. Keep Grinning.

 

I'm assuming that's the factory disc? I'm surprised to see an unsprung hub on an OEM clutch disc. Maybe that explains the dual-mass flywheel use then.

 

Yes, that is the factory disk in the pictures.