I had to replace the clutch in my 04 MCS about 3 weeks ago... I decided to go with OEM as I have read and heard of issues with some aftermarket replacement units... I had the flywheel resurfaced and installed a new rear main seal at the same time... It has been working fine up until yesterday...

Yesterday morning I began to feel a slight vibration in the clutch pedal when depressed... Also, the clutch will not disengage unless the pedal is all the way to the floor, whereas before it would disengage after being depressed about 2 inches... I am now having difficulty getting it into 1st gear as the clutch is still partially engaged even with the pedal all the way to the floor...

I know I'm screwed, but any one have any ideas? Bad throw-out bearing perhaps?

 

Clutch slave cylinder may have failed?

 

Some aftermarket companies are now offering upgraded TO bearings with their clutches. I just ordered a competition clutch with lightweight FW for my car. Got it from mini-madness. Helix also is offering a kit with upgraded TO bearing which is what is failing on most of the aftermarket kits that use OEM bearings....

 

Sounds like the TO bearing is failing or was not installed correctly. Did you have it replaced as well?

 

Yes, the throw out bearing was replaced at the same time...

The only other thing that took place on that morning was that I had the oil changed in the car...

Looks like I'll have to take it back to the shop where the work was done and have a 'conversation' with the owner...

 

One thing....
You "resurfaced the flywheel"...does that mean it is an aftermarket one...the oem one can not be resurfaced...the dualmass one...
It can deglazed, roughened up a bit with the likes of a Brillo pad...according to a few folks, but not "cut" like a traditional flywheel....

 

Sounds like a throwout bearing.

I second what Zippy said. Whenever I do clutches, unless the flywheel is in bad shape, we just hit the flywheel with a whizz-wheel scotch-brite pad and clean it up with brake-clean. You cannot resurface (cut) a dual-mass flywheel.

Good luck!

 

I wasn't aware that the dual-mass flywheels cannot be resurfaced... I asked the shop manager where the work was done to have the flywheel reconditioned... Perhaps I'm not using the correct term, as I have had other non-MINI flywheels turned to clean up the surface when doing a clutch job...

I'm out of the country right now on holiday so I haven't been able to get the car back to the shop yet... Back in la-la land next week, so I'll limp it back to the shop and have it attended to...

Thanks for all the input... NAM is a great resource for problems, solutions and enhancements to our cars...

Cheers and Happy Holidays...

 

Your flywheel may have been resurfaced. Not everyone can do it, but they can be. We have one shop here in Atlanta that can do it, I don't know of any others in town.

Check the slave cylinder first, then worry about the clutch.

 

Finally got Seccubus to the shop today and up on a lift... Looks like Way called it as the clutch slave cylinder was leaking fluid, so the seals are bad... New one on order and will be back on the road by Monday...

I am actually thankful that it is just the slave cylinder as I dreaded the thought of it having to come apart again... I'm already having withdrawal symptoms and need my MINI fix...

 

Harumph, I just got a call from the shop where I had (am having) my clutch issues attended to... They have replaced the clutch slave cylinder and it has not corrected the problem...

Next step, they are replacing the clutch master cylinder...

If this doesn't fix the issue, I'm going to get pissed because so far this is all on my nickel and it will most likely have to come apart, again... If this happens, the shop owner and I will have to have a discussion before proceeding...

 

That sucks. I wouldn't wish paying shop time for a MINI on my worst enemy.


...or would I?

 

Good luck with your clutch situation. I know how much of a pain in the *** it can be.

 

Got a call from the shop late this afternoon and my MCS is fixed... Replacing both the clutch master & slave cylinders fixed it... I guess it was just coincidence that these items failed less than 3 weeks after having a complete clutch replacement...

It was too late today to pick it up, so I'll have to wait till tomorrow to get my toy back...

 

I had nearly 100,000 on the 02 when I sold it. Clutch was as solid as the day I bought it . . .

Today the clutch on my 07 is solid too

as is the clutch on my 79 . . . sold my Miata with over 100k and the original clutch ... and an Audi Coupe ditto . . .

some people's driving habits eat the clutch

'twould appear that does not apply to everyone . . .

 

It's not a coincidence that replacing one component in a hydraulic system causes another to fail, especially if it is the same age or older. The new component replaces the weakest link that was lowering system pressure (i.e., by leaking or being overly compliant), and suddenly system pressure is increased and there is a new weakest link. This is why wheel cylinders (used in drum brakes, for you youngsters) should always be replaced by the axle, not the wheel.

Perhaps the higher spring pressure on your new clutch was just enough to overpower your hydraulics, causing the weak link to fail.