Last Week I just Finished installing a Rebuilt Super Charger and Took the Car for a ride! Still Heard too many noises and a few miles from Home I hear a LOUD Bank and like something left the car! I pulled over and saw that the Belt was still turning and everything was charging and working. I heard a Screaching and thumping sounds and slowly drove home. I am Wooooore out on owing a Mini!

I have a thread on everything I have replaced in the 8 years, 118,000 Miles and the $5,000 I have spend Doing "ALL of the work myself and paying about 20 to 30% of list!"

I have seen a lot in almost 70 years of life but never a Crank Pulley come apart! There was "1" Neat thing, The belt stayed on the car and continued to drive all of the Parts!

 

This failure is not uncommon.

 

Mine went around 75k...luckily a few days after we returned home from doing 3000+ miles for MINI Takes the States.

 

Common problem on 02-04's.
MINI did a mod on the crank dampers in 05 if I'm not mistaken.

 

I "Searched" this forum several ways before I printed this. I then went to Google and they had "THIS" forum with several problems like this. (It is a SHame I had to use Google to find what the Search did not show.) Because of all of this I found http://www.summitracing.com/parts/ATI-917992/ had the Dampeners for $338.95 but 20 day delivery. I am sure you can get this "Way" Sooner from Way . I simply cannot believe this car! I have never seen so many parts go bad in places other cars have never had a problem. There must come a time when I have replaced ALL of the Stock components and there will be NO OE Parts left to go bad.

Please let us hope that the Steel they used is not like the problem of the Lancia that simply rusted and fatigued away!! My Wife that LOVED this car is now saying Sell it for parts! I can drive the 1982 Porsche 911sc and spend a LOT less money on Repairs and get about the same gas mileage.
http://www.monte.plus.com/delta/del-buy.html

 

I just noticed the ad at the bottom of the page for Alexanderia Bavarian Service. I have been to their shop and this is also where I bought a Used Mini Head. They are all very knowledgeable and will treat you right!

 

We have seen a bunch of the crank pulleys fail. We actually did 2 this week at the shop. I'd say 80% of the ones we have replaced have been the 05-06 style. We always replace them with the ATI Damper since it is so much better made and dampens better.

 

They used steel in the Lancia???

 

All I can say about the ATI Damper is "WOW"!! The Instructions start at the beginning and end at the end down to removing the inner fender fastners. Second, it even comes with its own tool to install the damper. I DId not use the tool I went to McMaster Carr and got a high strength Threaded rod (12 MM) and some nuts and Thick Washers and cut the rod to length and using my Impact Gun (After Heating the ATI Damper on the Stove for a few minutes (very low heat) it went on Very Easy!

This is the first time I got something and it came with a tool plus no way to get better instructions! THANK YOU ATI Damper

 

I had my that went away at 30k... then put an alta 2%... wich i removed to fit a ATI damper!! That was an easy swap and it makes my car so much smoother to drive...
FYI I have replace 3 damper on friends' car in the last months.. all mini from 02' to 04'

 

I just keep staying amazed at the parts that fail on a Mini! At least here we all know that we are not all alone! I looked at your list of Modifications and see that you did not list the ATI.

Today I am buying a New Gas Cap. the only one is leaking pressure. I do not mind this so much as the fact that this car need for New Parts Never seems to end!