I recently replaced both drive axles left and right on a 2003 Mini Cooper S because of torn boots and a clicking noise from the right side when turning left. They were in bad shape. Along with the drive axles I also replaced the front struts, outer ball joints they were bad and outer tie rods because of ball joint wear. Along with stabilizer bar links.

I used the Bentley Publishers Service Manual as a reference along with this forum and You Tube videos to accomplish the work. The only thing I have done before but never on a Mini were struts. Everything went together ok and I did not find any of it beyond my ability as DIY.

When it was all together I test drove it for 25 miles both on residential roads and the highway with top speeds of 70MPH. Everything felt good and there were no strange sounds. The car was parked because I was going to make an appointment for an alignment.

Next time I drove it a total of 2 miles was on a residential road in third gear and it started making some bad noise which I can't describe as a harsh grinding but it did sound and feel like something was not lining up properly. Bad enough to pull over and call AAA.

Tow truck driver and I looked under car. Nothing hanging no signs of anything leaking. Tow operator started Mini and moved it slightly. From the outside the noise was definitely from the right side. Noise was only there when the clutch started to engage and not with car just idling. Operator said it sounded like the axle may have slipped out slightly. He said it happened to him after he replace a drive axle once. He suggested I start there.

Left side axle had a C-clip on it and when I put it in it made a pop which was C-clip locking in. New right side axle had no C-clip neither did old one when pulled out. Bentley Manual only talks about left side having C-Clip. I feel the bolts on the bearing shaft housing hold this side in. The right side didn’t necessarily pop in but I felt if intermediate bearing shaft housing bolts lined up everything was good. I have not gotten under the car yet but was trying to figure out where to start.

Anyone every put a drive axle in and have it slip out slightly?

How did you fix it?

 

Did you use OEM axles or aftermarket?

 

OEM Axles were used.

 

Sounds like you have the passenger side in right. It may be the carrier bearing if you messed it up putting on the housing. Or a wheel bearing that went just from working around it. Make sure your not leaking from the Axel's seals. I just replaced a passenger side Axel and it started leaking after that. Did it all again to replace the seal. Hope this helps A Curtis

 

Acurtis you are on to something. I had some time to look at it today with a friend. Started it up and let it idle. With car in gear and clutch depressed no noise. Put it in neutral and let clutch out there was a faint noise almost like something was vibrating. Turns out left side axle was moving up and down a little. No movement on right side which is were I thought noise was coming from. I guess my hearing isn't to good. Jacked up car with it running pulled left tire off and then noticed fluid coming out of axle seal. There was no fluid that I noticed prior to jacking it up. I think the wheel hanging while it is jacked up some how increased fluid flow. So problem is isolated to driver side. Weather was moving in so opted not to go any further. Unfortunately I have to work outside in the drive. Good thing is we were able to see a problem on the left side and as a minimum will need a new seal and will investigate C-clip once axle is out.

Next question do we just pull the seal with a seal puller. And could a bad seal lead to some play in axle? Any tricks to getting the new one in?

Left side drive axle seal leaking

 

You should not have movement up and down. There is a bearing right behind the seal. You can pull the seal with a big screwdriver just be careful of the case edge. While you have the seal out check the bearing inside. I used a 2" piece OF PVC about 3" long to drive the new seal in tapping around the edge. Good luck

 

In this pic it doesn't look like the axle is in all the way. But also that color doesn't make it look like an original MINI axle. Are you sure you have real Original MINI axles? We see issues all the time with aftermarket and why we don't even offer them.

 

 

So that rattling sound stopped after pressing the clutch, i have the same problem.. I heard that it is because Mini uses a dual mass fly wheel for the clutch system, and it rattles... So whenever it's time to change the clutch, it is recommended to switch to a solid mass flywheel instead...

Try to pop the axle out from the transmission again and when reinstalling it, make sure to SLAM it in there so that you know that it is fully seated... I am using aftermarket cv axle and have changed it twice already.. (My first new cv axel leaked 1 month of installing, but so far my 2nd cv axle doing good..) LOL