R50/R53 :: Hatch Talk (2002-2006) Cooper (R50) and Cooper S (R53) hatchback discussion.

R50/53 Stuck crush tubes

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Old Sep 16, 2025 | 11:09 PM
  #1  
slayslay's Avatar
slayslay
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Stuck crush tubes

This is driving me nuts.

I've got the vehicle in front-end service mode but can't, for the life of me, remove either crush tube. The 10mm and 2x16mm bolts are out. The tubes wiggle about 1/4" on the right side tube, and maybe 1/2" on the left (passenger) one. However, no matter what I do, I can't remove them. Here's what I've tried so far:
.
  • Tapping the front face of the tube from the back with a hammer, like in ModMini's videos
  • Yanking on it with gloves and my entire body weight... any more and I fear the car will come off the jacks (it's on all 4 right now)
  • Tapping a punch / drift into the edge of the outer sleeve, on the rear end of the crush tube, trying to push it forward with hammer strikes
  • WD40
  • CRC Screwloose Penetrating Oil on the edge where the outer tube wraps around the inner (leaving this one overnight and checking tomorrow)
  • A heat gun on high for 1.5 minutes, targeting area where the outer sleeve meets the inner, until the tube started smoking from the front by the bumper
I've tried wiggling in every direction, rotating, etc. It looks like it slides 1/4-1/2" inch forward, then gets stuck. I've got M8 200mm bolts already in place, ready to slide the radiator out so I can replace the damn CPS o-ring, as soon as these tubes come out. Car's actually an R52 but there should be no difference for this.

Save my sanity, please.
 
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Old Sep 17, 2025 | 01:30 AM
  #2  
deepgrey's Avatar
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Block of wood and a big mallet (or a drilling sledge if you’re feeling frisky), and don’t be dainty. They’ll come off.
 
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Old Sep 17, 2025 | 04:32 AM
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The thing with the tubes that make them sometimes hard to remove is that they are curved. Pulling straight from the front or tapping with a hamer will have them sit crooked and not in line with the subframe legs, which doesn't always work.

If you can wiggle them, great! What always worked for me is grabbing them with two hands fromt the front and wiggle up and down while pulling. They will move, millimeter by millimeter.

It will cost you some sweat though.
 
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Old Sep 17, 2025 | 06:10 AM
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As mentioned above 100%. Also once they are off, do yourself a favor and slather the rails with some grease! Once done it makes this battle easier the next time.

Happy motoring!
 
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Old Sep 17, 2025 | 08:38 AM
  #5  
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Originally Posted by deepgrey
Block of wood and a big mallet (or a drilling sledge if you’re feeling frisky), and don’t be dainty. They’ll come off.
Genius! That worked, thank you. I put the block against the back of the lower face-lip and it gave me the extra room to hammer it from behind.

Originally Posted by Scoobaru2010
As mentioned above 100%. Also once they are off, do yourself a favor and slather the rails with some grease! Once done it makes this battle easier the next time.
What kind of grease would you use?

Originally Posted by LukasH
The thing with the tubes that make them sometimes hard to remove is that they are curved. Pulling straight from the front or tapping with a hamer will have them sit crooked and not in line with the subframe legs, which doesn't always work.

If you can wiggle them, great! What always worked for me is grabbing them with two hands fromt the front and wiggle up and down while pulling. They will move, millimeter by millimeter. It will cost you some sweat though.
I've tried wiggling a billion different ways but, without a hammer, nothing worked
 
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Old Sep 17, 2025 | 08:48 AM
  #6  
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Yaaay! glad you got them off. I remember the first time removing mine it was more of less the same, pondering how the heck these things are still attached...

I slathered mine in some lucas red n tacky, although anything will help i suppose.

The CPS should be a breeze now, best of luck on the repairs!
 
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Old Sep 17, 2025 | 10:12 AM
  #7  
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Suggestion: Use Copper anti-seize lubricant when reinstalling. That will keep the two metal items from chemically bonding.
 
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Old Sep 19, 2025 | 11:25 AM
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Thanks guys!
 
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