I think there may be a good hand full of persons here who appreciate the one care Mini decided to utilize for WRC circuit and have seen the the multitude of videos that really motivate us to keep hold of and hopefully sustain the All4 manual countryman.

.... love that sound of the antilag!

I have been in an ongoing project of optimizing my mini countryman to be all that it can be with the help of my local mechanic and friend along with specialists like Lou from Prototype Tuning and RPM products for producing some necessary bits allow for some of the other mods that have optimized my motor (HP). Handling has also been fairly reasonable and accessible, with companies like M7 and other aftermarket companies that allow for mods to improve that are easily performed. But with all the improvements, mainly in horse power and optimization of HP mods these cars have shown a large impeding hiccup... especially in the USA!!! There are simply no improved nor service regions to deal with the failing Manual transmission Transfer Case.

I believe the transfer case is simply not up to the task of dealing with the capabilities of the modified 1.6l motors we have in them. My 10 yr old transfer case from my R60 JCW did not survive the brake-in period of my newly rebuilt n18 motor with custom exhaust header with garret 25-550 turbo pumping minimum ~250-300 (conservative) Hp during brake in. The brake in DESTROYED the internals starting with the bearings and proceeding to destroy the gears....

I had to resort to Europe to find solutions for the Case as over here we can only find rebuilt TC for manual transmissions that are more costly than new back in 2022.... they were around 2700new and now the rebuilt TC in USA are going for nearly 5000 dollars????
I think that there is likely a sustainable demand for providing a aftermarket transfer case (like honda billet ones for drag cars) that may revive the popularity and potential of this car.
Heck, even considering an sequential gearbox and transfer that could be applied would be awesome.

never the less... these are not the reality we live in. (if there are other options please let me know), so here my post is to point out possible resourses that you may look toward to help revive your modified Manual R60

https://www.gear-lab.co.uk/product/m...al-gear-box-2/
https://fmautoeservizi.com/en/catalo...man-28329.html

Best of luck with your ventures.
If anyone has found better luck with the transfer case solutions, please post.

Havy

 

If anything happens to my transfer case, Ive seen many on Ebay for $600-$1500 depending on the seller and where they are from. I dont think anyone sells post production "upgrades" for them, but if you've got money Im sure theres a handful of companies that would produce what you are looking for.

Link to various Ebay Transfer Cases:
$185 HERE
$530 HERE and HERE
$629 HERE

You could try your luck and message these guys from a custom gear set: HERE or HERE