Quick summary: '10 MCS MT 31K miles starts making noises from the clutch. The dealer pulls it apart and states that the clutch is fried and needs replacement. Because they see "signs of misuse" it's not covered by the warranty. I'm stunned. I've been driving 35 years with almost exclusively manual transmission autos. My daily commute is 80% freeway. This is my second new MCS, the wife is(was) considering the new SUV and I own a BMW as well. I ask them to go to bat for me with MINI and ask for a "goodwill repair." Later that day I'm told MINI flatly denied. The dealer offers $500 off the repair.

I have always been a MINI cheerleader, saying I've had no significant problems, and how fun they are. This however, is stunning to me. They can just walk away from an obvious warranty issue?? I'm now afraid to drive this fragile vehicle.

Just a friendly piece of advise to those that haven't been screwed yet. Beware!

 

Wow, have them show you the "signs of misuse" and have them explain why they think it's misuse. Take photos and have them sign an document with a full explination of the "misuse." If they won't sign it or provide a valid explination, then they are blowing smoke out their ... MINI HQ is only going off what the dealer mechanics tell them. If you need, have a mechanic friend be there with you when they explain it. That's just wrong.

 

That is pure, unadulterated horses#*t, the classic sign of a dishonest dealership who thinks they can bully you into paying them money for something they should fix under warranty. You may need to lawyer up especially if you're not up on car mechanics yourself. Ask them nicely who will represent them in event of a lawsuit. They must detail exactly what clutch part failed (not give the old "signs of misuse" excuse). Pix would also be good. The other thing to consider is moving the car to the other AZ dealership to fix. You didn't say which of the 2 you took it to. I bought mine at Scottsdale in 2007 (it was the only one). You shouldn't have to pay for it.

 

Yes make them prove your "mis use" like bald tires from burnouts or something.

 

They did show me the clutch disc with fine fractures and a ring of dust around the housing. They claim that means I was riding the clutch. I am absolutely a stickler for NOT riding the clutch and never leave it in gear at stoplights etc. I have had two other vehicles with more than 150k miles and have never even heard of a clutch going bad at 31k unless someone was racing it or doing full tilt drag type launches. I had to have my car back so I have paid it.

I'm not sure what BMW/MINI is thinking. I'm pretty much the loyal customer they should want to keep coming back.

Big Newt, it was the North end dealer.

 

I'm curious as to what kind of noise it was making. Mine has made a kind of "honking" noise on slow clutch takeup since around 10,000. It is especially apparent after a bit of stop-and-go traffic. If I'm extremely quick to engage the clutch; no noise. If I have to slip it a bit to get going just a few miles an hour it makes the noise during clutch engagement. I'm at a little over 40,000 miles now and no sign of slippage, just the noise after a little bit of use. Anyone else experience this? Thanks.

 

I've got 33,700 miles on my 2007 MCS. In the last several days I believe I've seen the exact same thing you're describing... a metallic "honk" while releasing the clutch from a standstill starting in first, typically after the car is warm.

This evening entering the interstate, I was somewhere around 2800 RPM going about 45 mph in fourth when I needed to accelerate to enter the middle lane. Depressing the gas, the RPM's shot up to ~4000, but the car had no noticeable change in speed. After a bit of a shudder, the car then began to pick up speed rather slowly. I'm guessing this was slippage. No CEL's or otherwise. I have an appointment scheduled to have MINI of Austin look at the car Monday morning. Of course my factory warranty is up October 31st... with such low mileage, I'm really hoping MINI will help me out if I'm looking at an imminent clutch/flywheel failure.

 

That is very similar to the symptoms I had. A groan with clutch take-up. There was never any slippage of the clutch however. Hope your dealer encounter is better than mine. GL

 

There are numerous threads like this all over about premature clutch failure. I would contact MINI USA and see of they can help you with this. I would also arm your self with printouts of similar threads to show that this is an issue.

Good luck as it will likely be a battle.

 

While driving into work today and out at lunch, I am definitely seeing a good amount of slip now. The honk/groan now occurs much more fequently, and is now appearing while at speed in between gears during shifts as well. The sound has almost developed into a 'whine.' I'm going to avoid driving this weekend and limp over to the dealer Monday for my appointment. I'm still hoping for help out from MINI under warranty due to my low mileage (exactly 33706), though not holding my breath.

 

Please let us know what the dealer says. Like I said, I've had the groan/honk, but no detectable slipping. And I've had the noise for 30,000 miles with no real change. I've also tried high MPH, low RPM, step-on-the-gas maneuvers like other have and it pulls like normal with no slip. That's why I haven't taken it in yet. Just a noise with no slipping.

 

Dropped the car off at nine this morning, had a call two hours later. Initially the SA suggested the "honking" noise was coming from a defective flywheel.

When I got the call, I was told the car was driven and slipping resulting in significant throttle revving was present. I was also told the tech "looked through a cylinder" and noted the presence of significant clutch dust, suggesting the clutch has been burnt. I was under the impression these cars did not have any kind of access point to inspect the clutch, so I'm not sure what he was referring to. I've called back a few times to clarify this point but the SA has been unavailable. I'd like additional clarity on where exactly the "burnt clutch dust" was observed as the car was not disassembled. The tech also noted presence of "fluid" on the bottom of the transmission, which the SA suggested was a typical indicator of a burnt clutch.

The SA quoted me a price of $1285 to tear down the car fully to inspect the clutch and flywheel, after which they could try to have the warranty cover it assuming the burnt clutch was not found nor burned spots on the flywheel. If the clutch needed to be replaced, the price was then $1631, and I would see an additional $991 if the flywheel was (very likely) required.

To be fair, yes, I did purchase this car with 27k miles on the clock. It is indeed possible the previous owner was a very poor manual driver. None the less with 33742 miles on this car, I've got to say I'm very disappointed. $2600+ to have the same potentially faulty OEM parts installed on my car seems ridiculous to me. Am I looking at only getting another 30k out of a new OEM clutch and flywheel combo? From my reading on this site and multiple others, that looks to be the case.

I'm also considering an aftermarket clutch and flywheel, specifically the OS Giken GT. I've read pretty much everything else is garbage, but I'm concerned about the longevity of the OS Giken GT as well. I'd hate to spend the $1800 for that clutch and the $1200 in labor to have it installed just to have it last me only as long as the OEM.

For now, it looks like the MINI will be living in my garage undriven for the next few months until I have the money to make a decision. I hope the rest of you with the "honking" noise can continue motoring trouble free for as long as possible!