Mini Cooper 2002 - Clutch problems

[Sophia21]

Hi there,

I'm really hoping someone can help or advise me.

I own an 2002 Mini Cooper and until recently it's been okay apart from several recalls over the years and the power steering pump and electrics failure. All of which resolved but understand are common design faults of the earlier minis.

About a month ago I noticed when I was on low revs trying to pull out into the road when I had the clutch down in first gear I could hear something spinning round and round. When the clutch pedal was up the noise would go away. This again would happen when trying to park and reversing and again the noise would arise when the clutch pedal was pressed down. I took my car to a trusted BMW mechanic who drove it around and and was convinced the clutch needed changing. By the time I had arranged to take the car into him the gears started to get really tight and harder to get into gear. In the meantime the spinning sound was more frequent, again when the clutch was pressed down and in gear. The nearest I could explain the sound would be like 2 metal dustbin lids the were not running smoothly side by side, a little tinny in sound but not very very loud but enough for me to hear it inside the car.

When the clutch was changed the car was given back to me to drive around but they warned me that the slave cylinder needed changing as the clutch pedal felt like a sponge and the biting point was almost down to the floor making the car judder all the time. The spinning sound was still there but initially less frequent. The gears were a little tight again and varied. I found it very hard to drive after an hour of driving as the gears became tighter to change.

I spoke to the mechanic who did the job and he was convinced that the clutch part is faulty and because the job was done privately but with a genuine part this time I had to go through the front door. Where I was told that if they take the clutch out and is not the clutch I would be liable to pay £900 for the time spend to take the gearbox out. My trusted mechanic was assigned to a bigger job that week and didn't think to ask for him specifically to do the work so they put someone else and by the sound of it didn't care much. They then charged me £125 to change the master cylinder hoping it would cure the pedal pressure. The pressure has improved but it has become impossible to change gears now and almost dislocated my shoulder in doing so.

Yesterday I got the car towed to the garage and just left it there. I'm really fed up with it and am really worried they are going to turn around and say it is my gearbox and charge me £900 just to take the gearbox out because they are trying to get to the clutch. I have specifically asked for the mechanic who changed my clutch initially who I trust 100% and he confident it's the new clutch but has to go through the master and slave cylinder first just to double check.

The car has only done 36,000 in 9 years and I hardly ever stay in gear when I don't need to but I do a lot of town driving which is a bit start and stop.
At this moment in time the car is impossible to drive, impossible to get into gear and the tinny sound is still there spinning away when the clutch pedal is pressed down. I have tried before to go into gear when the car was switched off and have been able to do so but didn't try yesterday when the gears became impossible to move.

Sorry for the long winded message but I am at the end of my tether with this and am worried BMW are going to keep charging me like money is falling out of the skies. I am going through the manager and have made sure I have my trusted mechanic looking after my car and I doubt it will happen.

Does anyone out there have any ideas, questions etc. They would be most welcomed and can pass these thoughts on to my mechanic.

Thank you

Sophia

[mab01uk]

I would think your 'trusted mechanic' should sort this out for you in his own time without charging you any labour if the parts he fitted are faulty or incorrect.

2002 Mini One and Cooper (up to mid 2004) are also known for early failing 'Midland' Rover gearboxes but the symptons you describe sound more clutch related. Should you need any gearbox information I have posted lots of info here:
Early MINI Rover Midland Gearbox - Forums

[Sophia21]

Hi there,

Thanks for your reply.
My mechanic has assured me he will get to the bottom of it even if he doesn't charge me his time. He doesn't think it's the gearbox but if he does notice that it could be the gearbox he will not log his time and let me know. I think it got a bit messy as he's an BMW employee and loads of them do work privately out of their hours and because what appears to be a faulty part and is under warranty I had to go through the front door.

I really hope you're right and it is the clutch.

Thanks

Sophia

[Sophia21]

Does anyone think it sounds like a flywheel problem?

Cheers

Sophia

[jimerl]

Don't keep us in suspense. How did it turn out? my 04 cooper started exhibiting similar symptoms Friday and I'm afraid to find out how much it's going to cost me.

[flying clutchman]

The original symptom you described is the classic symptom for the clutch release bearing wearing out. Fitting a new clutch (the bearing comes as part of the kit) unit should have solved the problem. The release bearing on this model is the same as fitted to peugeot/citroen models as well as rover 25/45 and is a little bit of a weak spot. To anyone reading this from the USA I believe your term for this is a throwout bearing.
Sophia I would'nt trust you mechanic too much in the future, he needs to fix this asap.