Got a 2009 Clubman. It's a diesel engined Mini. The clutch kit and flywheel were replaced in December of last year. The car is driven mostly highway and normal roads with basically zero stop and start driving. The new clutch has about 20,000km on it. I broke it in gently, etc...

Since the weather has been getting cooler I've noticed some funny problems arising. The first to develop is a rattling noise at idle with the clutch out. If I push in the clutch, the noise goes away. Sounds like a "dugga-dugga-dugga-dugga" kind of noise almost like a rapid tapping on metal. There is no noise when driving, only when the car is stationary and in neutral with the clutch out.

Second issue is that on cold mornings, when the car is idling and at a stop, if I push in and hold the clutch I hear a faint whirring noise like a "vrr vrr vrr vrr vrr vrr". Noise disappears when the clutch is released (i.e. I take my foot off of it.

Third issue is that first and second gear are sometimes difficult to engage. There is no grinding, but it feels as though it is kind of sloppy and not smooth engagement. So if I'm sitting at a stop and push in the clutch and then try to shift into first there is a very slight resistance, but no crunching or grinding. However, if I stay stopped and put it back into neutral and then try to go into first again, it's butter smooth. So the first attempt is always rough but the second attempt is always smooth.

What the hell is this on a new clutch kit? Is this the throw-out bearing? Input shaft bearing? Air in the hydraulic lines from the clutch change last year? Is my Getrag 6-speed box on the verge of failure?

Help!

 

So, on cold mornings you hear a tapping with the clutch not pressed, then when you push the pedal you get a whirring noise? Yikes...

The tapping that goes away when the pedal is pressed is very possibly something that has to with the transmission's input shaft. In my previous cars (two Hondas) that exact problem was an input shaft bearing that went out due to chronically low oil in the gearbox. (My fault both times! I figured out that I was screwing it up after the second one; I can be a slow learner.)

The other sounds like it has something to do with the throwout bearing. Perhaps the grease packed into it (if any is supposed to?) is too thick when it's cold?

I am very far from an expert, though. I can only share what has happened to me with my other cars. Both problems are potentially serious enough that you should talk with a good mechanic who knows MINIs.

 

Thanks for the reply. I've done some more reading and maybe I can rule out the input shaft. It's not a growling noise and there is no noise when driving. Issue only occurs at idle.

I'm starting to wonder if there is maybe air in the clutch line and the clutch isn't fully disengaging giving me some clutch drag - which would explain the difficult shifting. Perhaps the "tapping" I hear is the DMF and/or gear rattle. I find that if I increase the revs at idle, the tapping disappears. Could be some form of vibration.

Anyways, I'm taking it in on Tuesday because of the gear change problem. Also, the clutch feels a little "off". I think I'll have the dealer assess it.

I'll update when I have some news!

 

I think this in particular is normal. Both MINIs I've owned exhibit the same behavior.