I had the same "chewbacca" noise along with a noise clutch pressure plate (Spring wearing out unevenly). This is for my 2005 R53 S hardtop. This is a well known problem with the crappy OEM LuK sourced parts. The noise IS NOT NORMAL AND WILL DAMAGE YOUR TRANSMISSION INPUT SHAFT OVERTIME!
MINI replaced last week my clutch kit (Pressure plate, bearing, guide tube, clutch disk) and dual mass flywheel under warranty, no questions asked. I have 51K miles on the car and this is the second clutch replacement. However, the first time MINI replaced the clutch they did not replace the faulty factory flywheel.
There is a TSB out for this problem and affects all R53 and R52
MCS models from years 2002-2008. Your ticket is TSB # SI M21 04 08 dated September 2008. MINI will replace your clutch kit and install and updated flywheel part number on a "Customer complaint basis".
The new clutch and flywheel are a treat and my car now feels better than new. Don't live with this noise because you will damage the car eventually.!
