Hi everyone! My MINI 2002 transmission seemsto be dead and I need some suggestions on what to do next. Here is somebackground on the car and the problem.


I havea 2002 Mini Hatchback 5 speed manual transmission - 110,000 miles. I never had a problemwith the transmission before, never heard any grinding or anything. Only think I noticed was that during colddays in winter (I live in MA) it was a bit hard to pass to 2nd gear –I took it to the mechanic who said everything was OK- that happened only whenthe car was cold. Last week I was driving on 5th gear, stopped at alight and the shift was stuck- couldn’t move it at all (the previous morning Inoticed that it was a bit hard to put it in 5th gear but after thecar warmed up I had no trouble shifting gears, no weird noise so I didn't suspect anything).


After taking the car to a couple of different mechanics the diagnosis was: “broken linkage inside the transmission” (whateverthat means).


The solution they suggested: New transmission(with an estimated cost of $3300 for the transmission, and then add the laborand maybe parts of the clutch).


I know that transmissions can be rebuilt, so I called a place that works with Minis and the guy said that Mini’stransmissions can’t be rebuilt – that they can do that only in Germany… seems weird…


Anyways, now I have a car that doesn’t move (everything else is in perfect condition) and I already spend $500 betweentowing and diagnosis. I saw many threads of people rebuilding and repairing their Minis so I hope someone can chime in and answer some of my questions:

• Is it possible to rebuild a Manual Mini 5 speed transmission?
• Is it a DIY project or somethinga mechanic that has experience on transmission (even if not with Minis) coulddo? Is it worth it?
• Do you know what would be the estimated cost for rebuilding?

My current options seem to be the following

• Pay for the 3000-5000 newtransmission work – that is probably what the car is worth in working condition…and hope nothing else breaks since it is an old car.
• Buy a used transmission – saw onein ebay for 900… with the risk that it will also die
• Rebuild the transmission – if that is even possible
• Sell the car as is without a transmission… any idea how much can I get for it?
• Sell the parts

What do you recommend?


Thanks so much!

 

You can rebuild the Midlands 5 speed (2002-7/2004) and you can get the parts.

Check those shifter cables first on top of the transmission and the shiftier lug, make sure the move freely and are not stuck or seized.

http://www.realoem.com/bmw/enUS/show...diagId=25_0386

#1 and then look at #7 and #6 cables.




Then go to the transmission internals, open up the transmission and see what is broken.


Here is a DIY,

https://www.northamericanmotoring.co...mentation.html



If you cant do it yourself , I would get a transmission shop in your area to look at it that knows MINIs or BMWs.

Its one of the few MINI transmission you can get internal parts for.

http://www.ecstuning.com/Mini-2002-Cooper-R50-Base-Coupe-L4_1.6L_W10B16A/Drivetrain/Manual_Transmission/




Good luck and hope that helps.

 

First question we always ask our customers

How long are you planning on keeping the car?
If you plan on selling it right after a major repair then just sell it as it. If you are planning keeping it long enough you feel like you used the value of the repair you are about to perform then go for it.

Exceeding the resale value of the car with a repair is getting more common as they age but resale and "use value" are not the same. If you can get 2 more years out of it then it beats a car payment.

The midlands 5 speed can be rebuilt but all the parts have to come from UK since most dealers stock nothing for them. If you have not cracked the case it could be rebuilt but there are not many shops who will rebuild them since the process of ordering parts from UK is very time consuming and not profitable.

We had a customer who lost his 2nd midlands at 310K so we actually swapped it for a used 6 speed from Cooper S. It required lots of bits from an S to make it happen but grand total came out less than the price of a new 5 speed. With more Coopers ending up in salvage yards they are getting easier to obtain decent used parts for.

If you do go with a used 5 speed ask the yard about buying a warranty. Most yards will sell you a 2 year parts warranty for $100 or so. It won't cover labor but at least gives you piece of mind on the part itself.

We actually know of 1 DIY guy who purchased a crashed Cooper S just to get the transmission and swap parts for his Cooper then sold the motor and rest of the set up for minimal loss. Took him a few weekends but he made it happen.

 

Failing clutch slave or master cylinder can also make the shifting stuck like you describe.

 

Just playing with ideas here. When was the last time the transmission was serviced?.. If your transmission is low on oil, the wear on these components will accelerate significantly. In addition, shifting the car will be more difficult. One of the first things that you should check on a MINI that is having problems shifting is the level of the transmission oil. Could maybe start there. Here is a DIY for it. I had a shifting issue when the car would heat up because my fluid was breaking down under heat too quickly (everyone said it was my syncros). Changed the fluid and upgraded what I was using and never have had an issue since.

I also blew up my clutch on the track, but the way I could tell was when it was cold, the car would shift ok.. but once it would heat up, wouldn't go into gears. So a clutch issue is another option as well. DIY for it here.

Again, just all different options, but usually diagnosing a transmission issue by several different shops is going to be right. Since you already spent a lot of money, might be pointless to spend more on these things. The clutch replacement DIY can tell you how to drop the transmission. Might be able to do all that yourself, and the re-install, but take the transmission to a shop to get rebuilt. This can save you a lot of money on labor. Good luck and let us know what happens.

-Luccia

 

Thanks for all the suggestions! I read about the fluid before ... I hope the shops I took my car checked for that...
Maybe it started as a transmission fluid issue that ended in the transmission failing.
I like the idea of removing the transmission myself (my husband's self) and then take it to a shop to rebuild
I'll let you all know how it goes!!
Thanks again!

 

I'm stuck in the land of unsupported browsers at the moment but if you are DIY'ing the transmission be sure to watch the YouTube videos put up by "Mod Mini". He's got several R50 (which is the model you appear to have) transmission and clutch replacement videos. Some of them star the two cars my wife and I own! But it's not self aggrandizement here- he's really good and his videos are really helpful. Be sure to examine the clutch fork to see if it is cracked. He's also got a video about how to replace that- do not use a hammer!

That said, it's not an overly complicated job, it's just a bit time consuming. There's a lot of bolts to take off and you will need a few specialized tools, such as an engine brace to hold things in place while the transmission is out. Replace the clutch, of course, and I would suggest you replace all four ball joints while the subframe is out and replace the lower control arm bushings with the pre-pressed PowerFlex ones that Way Motor Works sells. With 110k on the clock your LCA bushings are almost certainly shot and the ball joints probably are as well. When it's all back together you will almost certainly notice improved handling.

Good luck and feel free to ask more questions.

Val

P.S.- thanks for saving another R50!

 

I was in the same position as you a little over a year ago. Car just wouldn't move pulling away from a stop light. If you choose to replace with a 5spd I can vouch for John Tee (mini gearboxes uk). While the 6spd conversion is the way to go, for some it's just not a realistic project time wise. My intentions were and still are to rebuild the one that came out and keep it around, god forbid.

 

Thanks daviday and valvashon for the suggestions. I will definitely check the YouTube videos.


I had my car towed home yesterday from the 2nd Mechanic and it now seems to be in first gear! I can't change gears but at least I can move it forward... very weird.
I will try the fluid as Pelicanparts said - I have some hope that the issue is as simple as that! (however the mechanic probably checked that already).


Whatever it is, it will take some time (months) to fix since we haven't done this before and we can put only a couple of hours per weekend... so I will update when I have more news!

 

Fluid should have been the first thing checked by mechanic and fluid does not usually mean its hard to get in gear, it just sometimes make the shifts smoother. It Automatics fluid plays a bigger part as it has to do with line pressure.

Good luck and from someone who has taken apart MINI Getrags and BMW automatics It can be a big job.

 

Thanks Everyone!!
It took a while but my Mini is running again! :D
Now the AC is not working... but winter is coming soon ...

 

Awesome, its been a while but great news.

 

Can you tell us what was done? Replaced the entire transmission? Part of the beauty of forums is that other people can find older threads that had the same problems as them and find the solution.

 

Yeah don't just say it works now. We want to know what you did!

 

Hi! Sorry, I thought it was implicit from the thread. We (my husband) followed the YouTube videos from ModMINI to remove the transmission. When we opened up the trans, the nut that holds the 5th gear on the shaft had come lose and locked the gears. We bought some of the parts from ECST and some from the dealer. We had no damage in the gears or selection forks, so ththe damage was minor. We didn't have to change the clutch flywheel since it was in good condition.
I'm attaching some pics.




Damaged gear bearing vs new one

Shaft nut that got lose and locked the gears

It took many weekends to finish, specially since we don't have a garage and was too cold and icy to work outside in winter, but we finally did it. It is a lot of work, but I love my R50 and couldn't let it go!

 

Congrats, thanks for sharing the pix! You're tranny experts now

Drive Hard. Drive Safe. Keep Grinning.