My nephew has an 05' MINI Cooper S, with about 58,000 miles. The car
is making a muffled, clicking/rattling noise that is very prounced
when the car is started cold. The noise seems to be coming from an area to the right of the top intake radiator (looking at the car from the front). The noise is much worse when its cold and appears to stop when the clutch is pushed in. When the car is warm the noise is not as apparent. The noise will come back when the clutch is let out in neutral. He's not positive but he doesn't seem to hear the rattling noise when the clutch is let out in gear and when the car is moving.

He went to a reputable mechanic who said the noise was coming from the transmission and that the transmission needed to be removed in order to determine the cause, at a cost around $800 to $2000 to fix. The mechanic said to check for any lawsuits or recalls against MINI regarding transmission issues. He's going to take it to the MINI dealer and have them take a look at it.

Has anyone here had a similar problem or know anything about any typical MINI transmission problems?

 

Sounds like a defective dual mass flywheel.

Some 2005s were fitted with defective flywheels from factory, causing rattling sounds and glazing leading to the infamous "Chewbacca" sound.

Do a search here on the following TSB: SI M21 04 08 dated September 2008

MINI released at some point in 2006 or 2007 a revised dual mass flywheel under part number 1 21-20-7-548-804.

The TSB recommends replacing the entire clutch kit as well if a new flywheel is put in:

Guide tube: 1 23-11-7-551-719
Clutch kit: 1 21-20-7-551-384
1/2 liter of oil 83-22-0-412-126

Replacing the clutch and flywheel takes 9 to 10 hours of labor (Engine and transmission have to come out).

At dealer's hourly labor rate you are looking at a $2,500 repair bill including parts. Can be done much cheaper at an independent MINI mechanic.

If you are still under warranty, bring up the TSB number I gave you (It is handled on a customer complaint basis) and ask to have the clutch and flywheel replaced under warranty due to known defects.

Good luck.

 

The MINI has crappy LuK branded OEM clutches and flywheels. Very well documented issues with these. The Getrag gearboxes are on the other hand very solid pieces of hardware.

Do a search for clutch problems. You'll get a ton of threads discussing them.

FWIW, my 2005 MCS has received 2 replacement clutches and flywheels in 52K miles, all covered and paid for by the warranty, no questions asked.

I had the flywheel rattling and chewbacca sound.

 

i have the same thing and havent actuall had anyproblems with it driving though mine is out of warranty though wich is why i havent gotten it fixed

 

Basically what you are getting is clutch chatter, it isnt really hurting the car it is just really annoying. My 05 does the same things with only 23k.

 

+1 on the dual mass flywheel noise. It is annoying but I've drivn mine with the noise for over 20,000 miles with no problems.

 

The chewbacca sound started at 28k miles on mine. Went away at 55k miles. Still working flawlessly at 70k.