Mini Cooper 2001-2006: How to Replace Ball Joints
The ball joints hold the steering knuckle and allow the front suspension to move up and down, while the front wheels steer the car. Obviously that's an important function. As they wear, they develop play and the accuracy of the front wheel motions suffer, messing up the go-kart like handling you love in your Mini.
This article applies to the Mini Cooper and Cooper S (2001-2006).
Ball joints are incredible components that are able to pivot, roll, and twist their way around, all while keeping the front suspension components held tightly in place. The Mini Cooper uses two ball joints: an inner and an outer. The outer one typically wears first, and connects the lower control arm (LCA) to the steering knuckle, so it has to deal with a lot of motion and abuse. The inner ball joint replaces what would typically be a rubber bushing on most cars, and connects one corner of the triangular LCA to the subframe. The ball joints are sealed units that will often last 100,000 miles; however, premature failure can occur if the protective rubber boots tear and they become contaminated with dirt. Not only does your handling suffer as they fail, symptoms of bad ball joints include a snapping or sharp thud when going over bumps as well as a wandering feeling in the steering. This article will outline the outer ball joint replacement procedure on the 2001 to 2006 Mini Cooper and Cooper S models.
To replace the inner ball joints it is suggested you drop the subframe, remove the axles, or unbolt the motor and raise it slightly to have room to work. Failed inner ball joints is much less common and so will not be covered in this how-to. If you are doing a thorough suspension refresh, or have signs of failed inner ball joints, you can drop the subframe and change them yourself, without a lot of special tools. You should plan on changing the inner ball joints, lower control arm bushings, and sway bar bushing while you have the subframe out, just to maximize your efforts. Details on how to change them are found here: Control Arm Bushing and Inner Ball Joint Replacement.
Materials Needed
- Floor jack and jack stands
- Metric wrench and socket set
- 1/4, 3/8", and 1/2" drive ratchets and extensions
- 1/2" drive breaker bar
- Ball joint separator
- Phillips and flat head screwdrivers
- Torque wrench
- Hammer
Step 1 – Lift vehicle and remove front wheel(s)
To access the ball joints, first lift and support the front end of the vehicle with jack stands and remove the front wheels.
Step 2 – Remove outer ball joint
The outer ball joints can be easily accessed and replaced without the need of disconnecting any additional steering or suspension components. Mini used a ball joint which bolts to the steering knuckle, and it is held tightly into a tapered hole in the lower control arm (LCA). With just the loosening of a handful of bolts and the use of a ball joint separator, they fall right out.
- Remove the large nut from the underside of the outer ball joint.
- Remove the two 13mm bolts securing the ball joint to the steering knuckle.
- Use a ball joint separator tool to press the ball joint from the lower control arm.
- The outer ball joint is now free can can be discarded.
Figure 2. Just these three bolts hold the outer ball joints in place. 
Figure 3. Remove the bolts and press the ball joint out of the LCA.
Step 3 – Replace outer ball joints
Installing the new ball joints is just as easy as taking the old ones out. Put them in their proper place, torque the two 13mm bolts to 41 ft-lbs (56Nm), slide the ball joint back through the LCA and torque the remaining large nut to 41 ft-lbs (56Nm). Now bolt the front wheels back on, lower the car and enjoy that tight handling the Mini is famous for.
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