Hi All -

I would appreciate any and all input you may care to share. I can tell the clutch on my 2004 MCS is about to go Kaboom, this is based on my research and the symptoms it's giving.

I am a bit at a loss as to what to do with the car at the moment. It's not a car I "need" per sa, but it is nice to have and a blast to drive. I have only had it three months and in that time, it has already experienced the following:

Broken Pax Window - Replaced with spares from spare 2006 MCS
Rear Ended while parked - Insurance fixed it, and it got freshened up a bit while at it - I got the hood painted.
Rear Tire Blow out - End up plonking a few hundred on TOYO Tires on all four corners
DINAN Exhaust - I just swapped over the modified DINAN Exhaust from the 2006 Parts Car.
I also swapped over the wheels and the Raceland Coilovers.
I also just paid for the registration to next year! LOL! SMH!

My initial dream.... I mean plan was to also swap over the DINAN Intake, the adjustable rear arms, the reduction pulley and as always suggested, the transmission and clutch pack from the 2006 since the transmission is supposedly better and will fit, and then also some other bits and pieces.

At the moment, feeling a bit deflated with this car - do I bother doing all this work to it or just sell it as is, or part it out and be done. Maybe I'll do MINI again in the distant future. My research shows that the clutch is an apparent weak point of the MINIs. I was recently quoted over $3K for a clutch replacement at a shop - with about $2.2K just for labour. Just how difficult or involved is the clutch job? I have a small workshop and work on cars, just not sure I am ready for this?

Also, should I bother swapping over the transmissions along with the clutch from the Parts car? The car will also need some other maintenance / repair items - leaking oil drain plug (was planning to swap lower oil pans), O2 sensors, Thermostat housing (small leak), Possibly Driver's Side Drive Shaft (I have a new one handy), etc.

Your thoughts, input, advice, suggestions and all will be greatly appreciated.

Cheers!



When I first got her.

How she looks now.

 

I feel you. I just put mine back together after waiting on parts and I still have old issues (random misfire and what sounds like cracked valve...).

If you enjoy the car, it can be worth fixing. I changed the clutch in mine this summer for a Valeo single mass conversion. I just pulled everything out from the front as I have an engine crane and it was the easier way for me to do it (and not having to deal with the steering rack/subframe laying on my back...), I changed a bunch of gaskets at the same time.

If you already have a donor car for the facelift 6 speeds, it's a no brainer.

 

That's really high for a clutch swap. A good indy shop should be about $1200 labor. Valeo single mass swap should be about $400 for parts, IIRC.

I f you've got time and ability, DIY. Pull the 06, prep, and swap should be relatively simple.

Sounds like you've had a few bumps, but once these cars have had their neglect addressed, they're pretty solid, and a lot of fun.

 

If you decide to do it this may help

 

Agreed with @Husky44 , you hit a few bumps when you care enough to build her the right way. So please try not to feel too discouraged!

Ive been hitting different bumps of my own for 10 months with my build.. finding and replacing TONS of seized or shot (and exorbitantly priced) fasteners, or swapping faulty/rusty subframe components I had not planned on touching. She’s dam near bulletproof at this point though.

Every effort you invest will be returned, and I bet the longer you have her, the less daunting something like a clutch swap will become.

I remember reading through for first thread with both cars and gotta say your 04 looks amazing now!

Take your time and enjoy learning these cars’ quirks. It’ll only make ownership that much more enjoyable in the end.

 

Guys! Thank you SO MUCH for the responses, it is really encouraging. It is very true that it feels like a non ending series of bumps with this car. As it is, I have other projects that I can attend to - I'm sure we all have similar things as car guys. I DO enjoy the car, it's a blast to drive and such. However, with current situations around, I am also trying to be prudent and not let this become a White Whale of sorts to me - I don't wanna be Abe! LOL!

I have to decide this week what to do with it. I have already invested a bit into it, I am just worried about sinking more and more money into it. If I can straight swap the transmission and clutch kit and all from the 2006, I might be encouraged to repair it and keep on enjoying it. Heck! I did register it for another year! LOL!

Does anyone know if the parts will be a straight swap from the 2006 to 2004? Or are there possibly some variances that will require modifications or such? I did look at the Valeo kit and I think one other one from FCP Euro which I have used a number of times. It was a thought. I also think I shouldn't waste the parts car I have since I have access to it. Might be an opportunity to swap out all the fun parts.

 

MAN OH MAN! For such a small car, it requires quite a bit of work. My M5 requires way less taking apart of the car for a clutch job! LOL! I am half way there with the 2006, I guess that helps a bit :-)

 

Couple of questions.....

1/. Just had a thought about the 2006 donor car. If I am able to swap the transmission from the 2006 to the 2004, can I just pull the complete transmission without taking off the clutch and all and just bolt it onto the 2004? Is that possible? That way I don't have to remove and then just re-install the whole clutch, etc.

2/. Was looking more into the Valeo kits and found one from Autohauz - Valeo Conversion Kit from Autohauz

Do I need anything else with this other than the fluids?

Here is the kit from FCP Euro, they mention you still need the clutch kit in addition to this? Is that an error on their part? Valeo Mini Flywheel Conversion Kit - Valeo 52151203 , from FCP Euro

 

I read the FCP site as trying to tell you that if you have the Valeo flywheel, you need to install a single mass clutch, not a dual mass. Both kits look to be complete.

I would be prepared, to replace seals, throw out bearing, etc.
​​​​​​Are track events in your future plans? This is the, tome, to swap in the LSD you're going to want. I regret not doing so.

 

UGH! Why did I for a moment think this might be different to BMW World?!?! LOL! The good ole, while you are in there thing. Track days are not planned, but you never know. So, can I just swap out the transmissions with the clutch still installed? And you are saying I should pull the LSD from the 2006? Did they all come with LSD's? Anyway to check and confirm it has one?

I've been told to also grab things like the S/C from the 2006 as it had better fans or something like that and also the P/S cooling fan from it?

 

I didn't do this job myself, so I'm speaking from what I remember of my research from almost 2 years ago. There are two seals that have significant potential to leak near clutch--IIRC it's the shaft seal on engine and input seal to transmission. I had mine done because it's a cheap part that's right there when you're doing the clutch, but buried deep if it needs to be done later. Same with throw out bearing. If I'm thst far into a tear down, I want all wear items refreshed while I'm in there. Not saying it needs to be done, that is just my approach to maintenance.

Limited Slip Differential was an option. Do a VIN decode to see if your car has one. It's one of the few options my car didn't have, and I now wish I had installed an aftermarket one when I had, the clutch replaced.

I'm not knowledgeable enough to answer the question about any variables from the 04-06 transmissions that would make a straight swap impossible. I think you can sawp straight across with no problems, but don't take my word for it.
​​

 

Didnt see if the question was answered but... no you cant... trans comes off the block leaving the clutch cover, disk and flywheel. There may be a pilot bearing/bushing, if yes, swap it. Best way to know if one will work on the other is to have them side by side and examine the cases for differences.

 

I'm with you about do it while you are there maintenance, it applies to all cars really. And with the MINI, with the amount of tear down involved, it's worth that little extra effort. The Seller of the 2006 told me the car has some sort of upgraded clutch so it would be an idea to see if it can be transferred. Guess first thing to do would be to tear down the 2006 to check all the components it has first.

What VIN Decoder can I use for the MINI? Anyone one know?

Cheers!

 

Thanks! Now that I think about it, you are spot on. Transmission comes off the engine doesn't it. No short cut there. Can the clutch and flywheel be re-used though?

 

@ssoliman - I look at that video again, he really does seem to remove a lot of parts off the car, including the subframe? The Book from Pelican Parts doesn't seem to involve that many parts. Interesting.

 

"Clutch Kaboom 'a coming.... What to do" <- Why would you want to reuse it? If it were a low mileage clutch sure no problem, you should look at it and determine what went wrong... If its a dual mass flywheel setup then trash it and go SMF.

 

Ummm.... I think we are talking about two different things here. I was not inquiring about re-using the clutch that is going bad. I have another MINI - a 2006. I was thinking of swapping that over as it is supposedly an upgraded unit and low miles.

 

Ah, gotcha... early morning fog for me lol Yeah if that clutch looks good and does not show signs of being overheated (clutch cover and flywheel as well) and if there is enough material on it heck yeah, why not?!

 

LOL! Tis officially known as pre-coffee fog in my household. If I get around to being able to remove the transmission and clutch kit from the parts car, I will post pics of the parts and seek your input on what it looks like - I am no expert on clutches and what to look for. I can kinda tell a glazed surface due to over heating, but that's about it.

 

yeah definitely post up pics of all the mating surfaces... on the clutch disk, you'd look at the amount of material extending beyond the rivets holding it together...

here is an example of a new clutch..

 

Quick Update: So, the clutch did completely go boom - so to speak. Not sure I mentioned that yet. Anyway, I had to transport the car to the workshop today. I was able to drive it in, when I say drive, I should say it was more of an adventure / mis adventure. From cold start, first thing in the morning, the car drove okay - shifted into gears and all and clutch would engage at like stop lights, etc. Once it was warmed up though and after a few miles, I had to rev match to make it up / down shift while driving. I unfortunately hit a bad patch of traffic just before my destination which did not help at all.

Once I got to my destination, I turned the car off to get the space ready for it - it would not start up again. It will now not start up at all - zero crank. It just clicks when the clutch is engaged or the pedal is pushed down. Battery seems fine. Is there a clutch safety switch that may have gone bad or did I just kill the car? I am now debating between fixing it, using parts from the donor car, selling it as if - not sure if anyone would want it (The issues would of course be fully disclosed), or just have fun and part it out. If I part it out, i'd keep the cool stuff and see if I might want another R53 MCS.

 

I understand your thoughts...sometimes a feel like I put way too much into this car

About the subframe. It comes out rather easily. I followed mod mini on YouTube and the Bentley instructions.

Your car looks really good. I bet you can get it sorted if you decide to go that route. What car would you replace it with? Or what car would you rather?

 

Strange that the car isn’t starting now. It could be the clutch switch, but check the ground cable on the passenger frame rail since it only takes a few seconds and a lot of non-start issues have been solved by making sure this connection is good and tight.

Not sure if it’s been answered yet, but ‘06 transmissions have lower 1st and 2nd gearing than prexfacelift cars. Retrofitting these 6 speeds on a pre-facelift car is a popular mod. Have you run the ViN on the ‘06 to see if it has a factory LSD?

Also, the thing about the ‘06 supercharger is it should have a different coating on the rotors to slightly improve the boost or efficiency. The facelift superchargers were JCW superchargers with stock sized pulleys.

 

It's a a bit of a tough decision to make whether to keep the car or not. Whether to even bother putting anymore effort into it. I really don't "need" the car, it is my fourth car. I don't think I would replace it if I got rid of it, I think I have enough to deal with LOL! I actually work on cars, I just don't know if I want to work on this one anymore at the moment. Feels like I am running into multitude of issues - some beyond my control though.

I mean I literally pulled up to a gate, shut it off, opened the gate and it would not start anymore. I just get a click. All the electrics work, car seems to prime up - but no crank, zilch! When I was caught in traffic that morning, there were a couple of occasions where I started the car and I could tell the clutch was not fully engaging as I had to cut it then restart it in gear to get it to move. Could I have damaged something that is now causing this symptom? And if so, question is whether it can be fixed or did I just finish the car off?

That lower gearing is part of why the swap was suggested to me. As far as the LSD, I don't know where / how to check the VIN on MINIs. Is there a link or site I can use? Thanks a bunch

 

I am currently debating if it's worth it to put time, effort and more money into this car. Of course, I am on a MINI Forum, so it is kinda a big ask since we love these cars. However, at 155K miles on the clock and what now seems to be dodgy maintenance history, should I just put the fun parts aside, part it out or get rid of it and seek a nicer example down the line?

One argument possibly in favour of the car is I do have a parts car, however it is a 2006 and so there are some differences in the cars. So far, I have taken wheels, coil over suspension, Rear Sway Bar (To be installed), DINAN Exhaust, DINAN Intake, adjustable rear control arms and some other bits and ends. If decide to fix the 2004, this would involve swapping the transmission, from the 2006 along with the clutch, then the reduction S/C pulley along with some more bits and bobbins.