My 03 MCS (72K) has been getting louder and louder. I would appreciate if you could help me figure out what the source might be...

1) When I start the car, during a take off without hitting the gas pedal too much, or moving slowly in traffic at low RPMs in 2nd gear, I hear a "metal to metal" clatter until the RPMs reach a "comfortable" level. I cant really locate this, but it seems to be right under the driver's seat -or around that area...

2) At high RPMs (starting 3K-6), there is an audible rattle. If I drive next a wall windows down, I hear it very clearly. If I increase the RPMs, the frequency of the rattle also increases. I hear it lot more from the passenger's side compared to the driver's... This rattle does not seem to happen when at an idle or just revving when at a full stop. While driving next to a wall, if I put it in neutral (while the car is still moving at a moderate speed) and hit the gas pedal, I still hear the rattle and it correlates well with the level of the RPMs.

My first guess is either the exhaust hitting somewhere or a loose heat shield. What else could this be? I have been reading posts regarding numerous rattles on NAM, and the scariest seems to be the supercharger rattle (especially since I have a 15% reduction pulley installed). Supercharger rattle appears to be different from what I am hearing, but just wanted to ask the NAM guru for an opinion.

I was thinking that it might be a loose motor mount. My passenger side mount was replaced, but that did not solve the problem. In fact the car seemed just louder right after the clutch was replaced around 52K. Since then, it is just getting louder.

Someone mentioned that low transaxle fluid may also sound like this, but I am not sure. Could that be a reason?

Otherwise, the car drives just fine and does not show any symptoms of anything.

Thanks in advance for your time!
Volkan

 

I'd like to think myself a guru.
here goes...

Was it a stock clutch replacement part? If the clutch you put in there was lighter than stock then that is where you get some of the noise from. It's like getting a lightned flywheel only not as light...i guess. The flywheel should not have been touched in a clutch only job. The mechanic may have checked tightness...eh the wrong way? How long ago was the clutch job? Did you break it in properly? Getting louder...Best take it to your clutch mechanic and have him listen.

My clutch is lightened, and it made more noise than the stock clutch. Strange at first, but I can't hear it anymore. But I really noticed when it I had an 06 loaner MCS for a few days.

Proper break in, that's no hard launches, keep it under 4k, no full throttle, no down shifting (heel-toe is ok though). I have heard before: "drive as if you have a cup of coffee on the dash." This is done for a minimum of 500 miles of CITY driving. I went to 700 miles, most of that being neighborhoods. Yes, I broke-in my clutch in about a week, with a few 8 hour days of driving. I really wanted to slam it again...

 

Thanks for the reply. The clutch replacement was done in July 06 when the car had 52K (now I have 72K). It was done at a dealer and a stock re-manufactured clutch was put it (they always do that anyways). They did not touch the flywheel. I believe that I broke it in properly. Upon picking the car up, it sounded "louder" for sure. A week later I went back and test drove the car with the shop forman. He gave me this strange look of "you are out of your mind, the car sounds just normal".

Himmm.... I thought I was done with clutch problems after going through 2 replacements. I really wish that it is something else.

 

Just my $.02 but sometimes clatter is an indicator of internal trans issues. Like two gears are not fulling meshing together and kinda banging off each other. And, any proper clutch job involves either a new flywheel or at least cutting the old one. Many placed won't warranty a clutch if the flywheel isn't resurfaced or replaced.

 

The clatter that I am describing only happens if I dont tap the gas pedal while taking off from a stop, or just cruising in 2nd gear with low RPMs. If I put the pedal down and release the clutch from a stop, I dont get the clatter at all... That's the ONLY time that it happens. Gear box feels the same as before too.

 

Let's say the clutch is the problem.

While sitting at the parking lot, if I rev the engine up to 5K, I dont hear the rattle - even next to a wall. It seems that the car has to be in motion for it to happen.

Here is my second question... If I am driving around 40 mph next to a wall around 4K RPM I hear the rattle. Then I engage the clutch, put the gear in neutral the rattle is not there while cruising in neutral. If I rev the engine to 4-5K RPM without putting in any gear yet -still moving around 40- I hear the rattle again.

Hope this helps in some way.... Thanks!

 

throw-out bearing?

 

or just heat shield rattling

 

I am certainly hoping for that If it is the clutch again, I am going to burn the car in front of my house and dance around the fire!

 

I'll bring marshmellows

 

Please do

 

the clamps that hold on the heat shield are rotting away. go underneath the car and take it off. it happens all the time

 

Thanks tech guy. I will certainly check the clamps once I have a chance... Unfortunately, my wife is car-jacking my MINI for a week to go to a conference and I will be stuck with the baby-mobile :(

In the mean time, I have been reading this old thread which describes the exact same symptoms
https://www.northamericanmotoring.co...ad.php?t=18230
The culprit seems to range from a loose heat shield to a harmonic balancer - or even to transmission.

Thanks again for any further insights in advance!

 

I just went to my local mechanic who works on BMW, MINI, Porsche, etc...

We drove the car for about 30 min. He did not hear the noise I was describing. They put the car up and checked for anything loose under. Heat shield was little wobbly, but the clamps, etc looked fine. The tech who did the inspection also took it for a test drive and he also could not hear anything "unusual".

I guess I'll just drive and keep an eye on it to see if it gets to a level where I can "convince" others that it is there...