I just picked up my '03 Mini Cooper S last weekend with 65k miles. As soon as I got it home (of course) it started up an odd clutch noise. It only happens when the car moves off from a complete stop.

The noise sounds like I left the parking brake on. At first, I thought it was a brake hanging up, but after some more "testing" I discovered that it happens at a certain place in releasing the clutch. If I move off very slowly with the clutch mostly pressed in, there is no noise. Release it a bit more and I hit the spot that creates the odd groaning noise. It also does it if I move off in second gear. Sometimes (usually after having been driven for a bit), it won't make any noise at all.

We tried flushing the transmission fluid and replaced it with Redline. Unfortunately, no change. Otherwise, the clutch feels great - no slippage, smooth shifting, no other strange noises.

Any ideas what it is? How to fix it?

 

1St welcome aboard. Nice MINI in your sig. IMO sounds like the clutch release bearing. Read these
https://www.northamericanmotoring.co...going-bad.html
Read the attached links in that post also. Good luck

 

Thanks Braminator! I read the information on that link - mine is not making a rattle, chatter, or sewing machine noise. It is more of a deep grinding/groaning noise. Pushing the clutch in and out while stopped does not make or stop any noises - it sounds completely normal until I go to drive off, in which case it makes that groaning noise.

Do you still think it could be the release bearing? Any ideas? I'm still pretty new to the working-on-cars-front, so please forgive me if I don't understand something

 

Does it sound like "chewbacca" groaning? From starwars....
If the answer is yes....
Then the flywheel is a dual mass flywheel, and the weights are sticking...and it can make a funny noise....the flywheel sound can be ignored till the clutch gets done....a dual mass cluch cannot be resurfaced.....they are kinda $$, so many folks install a cheaper conventional flywheel, at the cost of more nvh.

 

Zippy - that's hilarious and totally accurate. Sounds like a new flywheel is in order then.

Looks like there are lots of posts on replacing the flywheel, so will start my research...

Thanks again for your help!!!

 

Exedy replacement clutch + flywheel kit. Saves 11 lbs of rotational mass over the OE clutch/Dual mass flywheel setup. I got mine for $350 shipped from Amazon. Had it on for about 10k miles, no problems.

It is noisy, but nothing to complain about unless you're really fussy about these things. The gain in throttle response is well worth it.

 

Just keep in mind installing a non oem (read single mass flywheel) will change the driving/clutch characteristic. but this is a good performance minded option

 

One more question- is there any risk to driving with the chewbacca flywheel for a little while? In addition to being a daily driver, I plan to also use it for some light autocross use. Do I risk damaging anything or will the noise just continue to be annoying/embarrassing?

 

You can safely ignore it....
Then when it is clutch time, decide what to do. No rush.
Choices are, oem, an aftermarket dualmass is arounf for about $50-100 less, the a regular weight conventional, or a lightened one of various weights and materials.

 

My wife has been driving with chewbacca for probably 65,000 miles (on and off) in her '03 MCS without issue. What's going to kill the car is the need for repeated top-end rebuilds. For some reason, it seems like it likes to burn valves.

 

Hmm..another possibility could be that your hill-assist isn't releasing correctly. Do '06 cars have that option?? Sounds like they nailed it above though and that sounds way more likely.