I just finished going through the records on my new-to-me 04 MINI. Here are the unresolved problems I found

Rear engine seal leak
Rattle at idle in clutch or flywheel
Oil pan seepage

I did my research, I see these are common problems. The threads I found didn't mention costs, most of the people with the problems were lucky enough to be under warranty. How much does a rear main seal cost on a MINI? Also, I assume the rattle is a bad flywheel, which I suppose I should replace while I have it all apart to get to the seal.... I guess that's an excuse to add light weight flywheel to my modification list.

Car has 34,000 miles on it, the problems were diagnosed at 31,400 miles. Brecht BMW diagnosed the rear engine seal and clutch/flywheel, the previous owner then took it to an indy to get some of the other recommended work done, they then diagnosed seepage from the oil pan... I think a visit under the car is in order to see if this is two leaks or a misdiagnosis from one of the shops.

Last question... how long can I go without fixing the engine seal? Is it an ASAP job, or more of a when you get around to it deal?

Gracias.

 

Not sure the rear main seal is as common as the crank bearing seal on pulley side. Changed mine when adding the updated crank pulley from the 05/06 models. It was leaking and replaced all at once, along with a pulley tensioner stop from Alta. What the heck, as long as your there right ?

The MINI oil pans are as you found out, natorious leakers. Second only to a Harley Davidson.

When removed, have it put into a parts washer, they come out like brand new. You may want to consider adding a baffled oil pan insert ? Esp if you have any plans of tracking the car in the future.

The sound you seem to be describing is more likely to be the throughout bearing. Also a common issue. Mine had made some noise for last 30K miles.....gonna run it like that until it doesn't move anymore. As far as a light weight fly wheel goes....I look at those same as an undampened light weight crank pulley - Unless you are going to run 1/4 mile tracks, and not a daily driver and have the extra $ to get in there for replacements/repairs every 20K or sooner, you would be better off sticking with OEM clutch assembly.

 

Thanks for the help. I asked my friend who used to work at MINI Corsa and he says he thinks it is the throwout bearing as well. He's going to look at the car this week to confirm his suspicion and to see if the leak really is the rear main seal or if it is coming from somewhere else.

 

If the rattle noise in the clutch goes away when you hold the pedal down, it could just be the dual mass flywheel, in which case leave it alone - it won't hurt anything.

A seeping oil pan really isn't a problem either, most of them don't leak enough to make a spot on the ground - if your's is this way, why bother with it?

 

Yes the oil pan gasket is very common. DIY project done for the cost of a gasket ~$20 if I remember correctly.

Clutch noise - get used to it, mine has done that forever. As MiniDave said it might just be the dual mass flywheel. I'm over 228,000 miles now, and I know its been making noise for at least the last 100k.

Nik

 

I haven't heard the noise yet. It didn't make the sound when I test drove it or drive it the first few days I had it. It's with my bf right now getting the HK system ripped out. He heard the noise once on start up, when he clutched in it went away. He described it as a rattle. That's the only time the sound has presented itself in the ~400 miles I've had the car for.

Wow, thanks Nik that makes me feel better. My friend says that if it is a bearing I'll have to replace it before the clutch stops working, but if it is a flywheel I guess I'll save it for later... or for when I do the rear main seal if that is really what is seeping.

 

Ok, report in from SO, sound happened again this morning at start up, but as before, went away when he clutched in and didn't come back.

 

You have all the symptoms mine has now. Still running it. The chatter is definitely the flywheel. It's annoying as it sounds like a helicopter. I talked to Waylan at Way Motorworks and he says that my oil leak is the oil pan gasket gone. It looks bad, but never lose enough to drip on the ground or to lose any to replace. He says that the rear main seals can go, but aren't that common of a problem. Does your clutch slip any? Mine does only on takeoff. Definitely sounds like a glazed flywheel. Keep us posted.

 

Befor you go into all that work I have had this issue and had the car in the shop at least 10 times and finally they told me the secret. If you let the clutch out really fast in nuetral it will rattle like you are saying but if you let it out slowly it will not rattle. if it still does push it in again and let it out slowly again. Soon it will become a habit when ever you go into nuetral. They told me with the hydralic clutch, if you let it out fast there isn't enough pressure to get that throw out bearing in the correct place so it doesn't rattle. so if you do it slowly, it will keep enough pressure to move it to the correct location. The dealer said it wont hurt anything when it is rattling.

 

Cool, I will give this a try.

 

That may be while I've never heard it, I'm not one to jab the pedal. I told my bf to be easier when releasing the clutch to see if that stops the noise.

Thanks!

 

The earlier cars are also prone to a noise - referred to as a "Chewbaca" sound, usually the first time you let out the clutch in 1st gear after starting cold, and usually more evident on cooler or even cold days - don't worry about it if it does that, it's just the dual mass flywheel again.

Unless you car is leaking a lot of oil and leaving spots on the ground, I wouldn't worry about it.

 

Just remember to check your oil frequently!! You know you have a bit of a leak...so check it regularly, and you will know when the level starts to change faster, it is time to get it fixed!!

If you forget to check your oil....the problem will go away since the leak will stop when the motor runs dry, and the RED OIL PRESSURE LIGHT turns on, resulting in you needed a new/rebuilt motor!!!

 

My 04 just started making that "chewbaca" sound exactly as described in the morning, so its really nothing to worry about at the moment? It does not seem to do it at all after car warms up.

 

It's not a problem, ignore it if you can....

 

Wierd.....or what. Few hrs ago I was doing just that and found out same thing. While parked, if I let the clutch out slooooowly, the clatter is not heard. Pressed it in, let it out quickly and sound came back with a vengence.....

I hear the TO bearing is made of plastic. Anyone ever make an aftermarket one of other materials to eliminate the noise ?

 

The sound comes from the Dual-Mass flywheel getting stuck (think of it as (over-simplified)a two pieces of metal, with a gel in between it...and the gel lets the flywheel absorb some vibration, and "twist"or torque a bit-from what I have been told anyway, and sometimes due to age, wear, defects, it sticks)....is sounds bad, but does not affect the drivability/relalilibility of the car...from what I have been told.

 

I'll be d****d if this didn't work. WOW, that was really cool. That chattering stopped......for now at least.

 

Just teach your self to let the clutch pedal out slowly when parked or stopped. It will save you more time and money about thinking y that rattles

 

I have had the same problem, the throwout bearing rattles when cold or releasing the clutch "normal" when you release the clutch slowly, no noise, this can be lived with but last week the clutch was making the same noise but in addition to this was making a grinding, wining nooise when pressing the clutch, I could alos feel it throw the peddle, just didn't feel right.
I had a garage look at it, they confirmed the throwout bearing was the issue and stripped the clutch, only to find...

the clutch fingers bent and pressing the bearing at an angle which was distorting the pressure plate and overheating the complete assembly, I bourght the car second hand and they told me it was due to resting your foot on the peddle while driving, so keep your foot off the peddle,

the cost is R5500 total, new fingers, bearing, friction and pressure plate, skimming of the flywheel, labour....

not what had expected to happen on a can with only 100,000km, but one of thoughs things, hope thats it...

be warned.

 

Nope..it's the TO bearing. It is made of plastic and tends to "float" if you let the clutch out fast due to the lack of back pressure keeping it properly seated.

If you just release the clutch slowly, you will not hear the "chatter"......I have heard owners complain of replacing it, then only to have it re-occur a few thousand miles later....just have to learn to live with it.

 

Gray Raven, you are right. I thought the aftermarket throwout (i.e. release) bearings would be steel, but they are all plastic (i.e. nylon?) for the MINI. I bought a Spec Stage I clutch kit for my old '02 MCS and never got around to installing it before it was totalled. It's been awhile since I looked at the kit.