I will be posting my build progress here, as I have already started and accumulating parts to fix it up and modify it as much as I can. Its a 2004 mini cooper S. I got it about 2 years ago knowing it was leaking oil, so I drove it about a year leaking lots of oil, about quart every other week. Oil was coming from the valve cover and crank sensor mostly, maybe front seal also. I purchased all the gaskets for everything except the head (good compression) car has 160k miles on it. It also had a broken belt tensioner on it when I got it and I still drove it like I stole it LOL. Here is a pic a few weeks after I got it home.

 

The first thing I noticed was the suspension was totally shot, so I ordered this set up

https://shop.redline360.com/products...iABEgKrH_D_BwE

with trailing arms.

I have to say this was beyond my expectations, I wasnt expecting this set up to be as good as it was. I needed new rear upper bump stops, totaly gone stock ones, the new coil overs dont come with any. The new bump stops bushing had to be drilled out some to fit the bolt.

 

Now that I got her to ride right, it was time for some new shoes! Got some 17's with track only tires mounted, they are super wide so I needed spacers to clear the front suspension. They also needed the center ring spacer as the rims hub ID was slightly bigger than stock. Now we have grip! She turns soo hard that the passenger will end up on your lap! LOL.

 

After the new shoes I ordered a Borla cat back exhaust, she sounds way better now, but not quite loud enough. Soo I ordered a MilteK header with cat delete race pipe (still not on yet) sound clip to come after tune.

 

So here is the current status as of last weekend. Pulled engine and trans. It was a mess, at least the oil leak prevented any rusting LMAO. Oil everywhere. I used a flat razor to scrap off most of the oil build up. I pulled the stock pulley off and everything else that need a gasket and or attention. New timing chain and guides/tensioner went on first, oil pan gasket, timing chain cover gaskets, new idler pulley, PRW fluidgel Damper crank pulley, new front crank seal also, there is also a little tiny o ring that goes in the center of the timing chain cover with the bolt as a washer, that I wouldntve known about if I didnt look at the assembly print. Now I had to work on getting the stock SC pully off, I highly recommend using the SC pulley tool! I ended up going with 16% under pulley recommended from Jan at RMW, at first I was going with a 4% over lightweight crank pulley, but after discussion with Jan I opted out, due to stock supercharger RPM. I also replaced the oil filter housing gasket and oil cooler gaskets and all hoses.

 

This weekend, involves removing clutch and trans to get ready for new fx400 clutch and new one piece steel flywheel. And quaife LSD on the way. Pics to follow.

 

While waiting for parts today I replaced the old worn out shifter boot and e brake boot/handle

 

Today, replaced rear main seal, got the new clutch, took the old open diff out, new lsd is arriving today! New flywheel arrives tomorrow I think.

 

Ordered new spring clamps for the mishimoto hose kit I got, since non of the stock ones fit due to the hoses being thicker. While I was on Amazon ordered some new t-bolt style clams for the intake hose, I like the way those look better. Soo far looking like engine should be back in by next week.

 

New quaife lsd came last night, just pressed on the new bearing at work this morning, ready to install and re assemble gearbox, then flywheel arrives today, and get the that bolted on and new clutch. Then pick it up and bolt it to the engine to put back into the car! Cam and tuning software wont be here till next week, so I will throw that in when it comes.

 

New flywheel and clutch bolted and torqued. New lsd installed and sealed.

 

Let us know if the LSD makes a driving difference (like can you actually feel it?).

 

Well my weekend started off with a broken transmission housing as I went to assemble the trans to the engine the back end was cracked in half 🧐. Soo luckily my local salvage yard 1.5 hours drive had spare used one for 350$ I drove out and got it back to start diss assembly of the broken on to get the lsd out to put it in the new used one.

went to remove the broken clutch slave off this used one and both heads of the bolts broke off, ugh. I’ll drill them out later I said.

got everything assembled and back onto the engine!

today I got it back into the car finally! Bolted the new header on, and fished some coolant lines together, now I just need to take my time hooking the rest of this ****.

 

Nice work! crazy about the transmission....it's always something. I just got my engine back in yesterday too and I'd like to know who thought bolts for the header were a good idea! I struggled with those for a good hour and a half.

 

Really? It went pretty easy for me. It would've been more difficult if the intake manifold was in the way or more of the front end was assembled. I also had the coolant resev out the way too.

The dominator cam arrives today! Looking forward to another hour or so of bolts lol...

I did end up snapping the bottom of the map sensor off tho while installing the trans yesterday, should've removed it but my stubborn butt was determined.

 

This diagram deff helps!

 

They have arrived! time to install the cam while still in front end service mode.

Thanks to @Revolution Motor Works

 

pic before removing stock cam.

one trick was to leave the cam sprocket tool attached to the sprocket as you pull the it off the cam so it never moves or skips any teeth. After removing tensioner of course.




Cam installed and torqued down, partially assembled. Just through the red stuff on to see what it would look like. I also installed the 550 injectors and pig tails. I must have the wrong belts, I can’t get either of the two I have to fit.

you also have to ping in the spark plug tubes because the lobe of cam hits when it comes around about .010-.012 thousands of an inch. I used a ball end of a small hammer.

 

Got the axles back in, hooked the power steering unit up. Put on the plastic pos that hooks to the throttle body lol.

now I just need to fill the gears with oil, and plug the wires in and hook up the front end back up to fill with coolant and bleed the clutch. Then work on tuning it.

 

Nice job, you’re working fast! Mine has been pretty much ready to go since last week, but one of my axle boots tore as I was re-installing it…it was very thin/flimsy feeling so I’m glad it broke now and not while I was driving. Still waiting on the new boots to arrive before I can drive it :(

 

I just went and got two new axles. Both of my boots were torn and the axles came apart when I pulled them out, they were cheap enough to buy new imo. One was 89$ the other I think was 100. Through ecs.

it will be a while before mines ready, I’m having shoulder surgery on Friday. So I’ll be down for a bit.

 

ouch, good luck with the surgery. And let me know how the axles are. I've always had terrible luck with aftermarket CV axles generating vibration during acceleration, so I try and rebuild my originals whenever I can. In my case, I didn't drive with a broken boot, so it was an easy decision.

 

Today I hooked up power!! Just to download the ecu in my dimsport so Jan can make a tune for me to upload. Was kinda scary hooking up the relay box correctly it took a bit of searching for the pic to look at. There are a few that can be interchangeable.

 

Good luck with the build! I installed a Quaife in my old '03 and it was a huge improvement. Much better than the OEM LSD in my GP! You'll enjoy it once it's all back together!

I have a cam sitting in my barn. How was the install? Any issues with the tensioner? Will you be doing a break in for the cam when you first start it?

 

the install was super easy, the hardest part was getting something under the engine to support it because you have to remove the engine mount. You do have to remove the tensioner and when reinstalling just push the tensioner pin in all the way with your hands until it locks in to put the bolt back in easy. Just watch modmini you tube video.

as far as break in, I don’t plan on it, just drive it like I stole it.