On my 2004 Mini S, for a few weeks now, every now and then the clutch wouldn't return and because of that I couldn't shift into gear. This only happened at slow speeds. I figured out that I could pull the clutch pedal up with my foot and everything worked fine. So this was intermittent. When I was out yesterday the clutch went to the floor and pulling the pedal back up didn't help. I figured the piston seals went bad. It was a real hassle driving it home in 1st year, especially at stop signs (I avoid stop signals).
I have not done this type of work, but I am asking what do I need to do to fix the issue and is it a difficult process? I am guessing I just need to replace a master brake cylinder, but I don't know, so I am asking for you guys to give me direction. I could take it (flat bed it) to a mechanic and he could do the work for about $300-400 or I could since the mechanic says he's busy for the next 3 weeks.

 

Only you know if you're capable of doing the work yourself.

Watch the video and see if you think you can tackle it yourself.

Mod mini doesn't have a video for the master cylinder which might also be the problem. I haven't personally done one a mini so I can't say how hard it might or might not be.

 

The question I am pretty sure I can do the job. Last year I did the rear struts and one half shaft. I just don't know what part to replace.

 

It sounds like it's a hydraulic issue so it's either going to need a slave or master cylinder, or even both possibly. Can't think of any other parts you might need. The lines don't seem to go bad on our cars.

I would get under the car and inspect the slave for any leaks.

 

What about the clutch master cylinder under the driver's side dash?
Should I just leave it alone?

http://www.pelicanparts.com/techarti...eplacement.htm

 

With the help of my wife I was able to flush the clutch and there was some air but not a lot.
The issue I have now is that the clutch pedal never returns. I am under the car and I tell the wife to press the clutch down and hold it down. She tells me it is down and she doesn't have to hold it down. I open the bleed screw to let fluid out and then I tighten the bleed screw down. I want to check again for any air and I tell the wife to pull the clutch pedal up and then push down. I open the screw again to let fluid and any air out again and then tighten the screw back down again. I checked it and the pedal is part way up but not quite parallel with the brake pedal as it had been before. When I press the clutch is goes down a certain distance and is rock hard but it does not give as it did before and you knew you the clutch was engaged and you could shift.
I don't quite understand why the pedal is not returning all the way and is not allowing me to shift.

 

Are you certain that the control spring (#7) hasn't somehow bent our come off?

http://www.realoem.com/bmw/enUS/show...diagId=35_0267

 

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My only thought is that there's still some air in the system...
Either there's a seal that has gone bad (usually the slave cylinder) or that the reservoir got too low and allowed air in the system.
Did you compress the piston shaft for the slave cylinder when you and the wife were bleeding the system, this "must" be done.
If so, if day replace the slave cylinder, the above video is pretty detailed and should give you everything you need to do the job.
Good Luck

 

Found the problem and it was so simple I cannot mention it here for I will be forever banished.

 

Nonsense, "shame only makes you human."
Glad you found it anyway.

 

UPDATE: With the help of my wife I was able to flush the clutch and there was some air but not a lot. Buttoned everything up
Flushed out a few more times. There's quite a bit of pedal travel before I am able to start the car.The pedal doesn't feel solid and I can't engage the gears.
So I am back to where I started from except now I have a new clutch slave cylinder.

 

You either still have air in it, or the clutch master cylinder might be bad.

Try the board on the clutch pedal overnight trick and see if that helps.


https://www.northamericanmotoring.co...and-slave.html

 

Yes, I made up something to compress the piston. Flushed the system at least 6 or 7 times and then buttoned everything up.

 

and it's fixed?

 

No, check my update above.

 

When my clutch pedal went to the floor and wouldn't return, much like the symptoms you're having, my pressure plate exploded.

See attached pictures.
Replaced with OSGiken.




Shiny and new.




Just my experience. And I don't think the pressure plate fracturing like that is normal, the clutch just couldn't handle what the engine was giving it. Overheated. And done deal.