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R56 '09 S R56 Clutch fail

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Old Jun 27, 2015 | 10:09 AM
  #1  
RockyR's Avatar
RockyR
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'09 S R56 Clutch fail

My clutch failed at 66,000 Miles on my '09 Cooper S. It never slipped and the only indication something was awry was a slight groink on occasion when taking off in first gear - had been only occurring for the last five hundred miles.
Failure was as such : slowing down to stop, foot on clutch, light turned green, shift into second, released clutch, hit gas and whirrrrr....... motor revs, no forward motion ! All friction material had spun off the clutch disk into a big smoking birds nest of bad smelling stuff in the bellhousing. There was smoke !
Independent shop cost to repair with LUK replacement kit was 400+800 parts and labor ( US$ ). Flywheel and shift fork was OK. My driving style is spirited, but I don't think I abused it.

I think life was less than expected and I'm miffed that it left me stranded rather than slipping or warning me ahead of time, but I'm glad I didn't get raped by my mechanic. He did complain that book hours (alldata) for this job was less than actual, so perhaps I did get a better deal than I should have.
Just wanted to share so that others pay prompt attention to their funny clutch noises!
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Old Jun 27, 2015 | 01:41 PM
  #2  
Systemlord's Avatar
Systemlord
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From: Mission Viejo, CA
That's go to be the worse looking pressure plate I have seen, I'm used to seeing the pressure plates fiber based material being a shiny surface. You don't have any material, I believe your pressure plate died prematurely do to the material coming off kind of how brake pad material fall apart from the backing. Recently I all my clutch components replaced and my flywheel looks much worse than yours and I still had more life in my clutch parts. I'm at 62,000 miles now and my old clutch could have made it another 25-30k miles.
 
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Old Jun 27, 2015 | 04:56 PM
  #3  
minivinnie92's Avatar
minivinnie92
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From: Jersey
'09 S R56 Clutch fail

I made it 38 k with no slip no noise even the pedal felt good than I went to shift to third heard a grind wouldn't go into third or any other gear. I fought with my SM and said this is bull 38k just ain't right my VW was 155 k still in factory clutch I mean between me and you more than half dozen autocross events and half dozen 1/4 mile launches on a stage 2+ manic tuned car so it probably got abused pretty good but still never had a warning sign very weird
 
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Old Jun 27, 2015 | 05:17 PM
  #4  
Systemlord's Avatar
Systemlord
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From: Mission Viejo, CA
Originally Posted by minivinnie92
I made it 38 k with no slip no noise even the pedal felt good than I went to shift to third heard a grind wouldn't go into third or any other gear. I fought with my SM and said this is bull 38k just ain't right my VW was 155 k still in factory clutch I mean between me and you more than half dozen autocross events and half dozen 1/4 mile launches on a stage 2+ manic tuned car so it probably got abused pretty good but still never had a warning sign very weird
The OEM clutch wasn't designed for autocross and the insane torque that the Manic tunes offer, it sounds like your a little more aggressive than I. I have seen clutches go bad but this was on factory tune cars, the tunes must really heat up the material on the stock pressure plate. Did you go for a JMTC stage 1-3 clutch? If I ever need a new clutch I'm installing at least a stage 2 clutch SMF. That's how most clutches die, without warning, I have had many clutches fail with no warning.
 
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Old Jun 27, 2015 | 05:21 PM
  #5  
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minivinnie92
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From: Jersey
'09 S R56 Clutch fail

well see since it went right away I kind of wasn't prepared for it and itbwss a Thursday was going away that weekend and my service manager got it don't by 4pm Friday for me and I paid 0$ so I just went with the oem clutch and new flywheel and all eventually I will just upgrade and order a stage 2-3 clutch from jm not sure if I want to swap to a light weight smf either going to cross that path when I get there
 
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Old Jun 28, 2015 | 01:20 AM
  #6  
Systemlord's Avatar
Systemlord
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From: Mission Viejo, CA
Originally Posted by minivinnie92
well see since it went right away I kind of wasn't prepared for it and itbwss a Thursday was going away that weekend and my service manager got it don't by 4pm Friday for me and I paid 0$ so I just went with the oem clutch and new flywheel and all eventually I will just upgrade and order a stage 2-3 clutch from jm not sure if I want to swap to a light weight smf either going to cross that path when I get there
I would prefer the lightened steel flywheel rather than the aluminum, plus you can resurface the flywheel and reuse it.
 
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