An official answer to the howling clutch and gearbox.. (Cooper S and Convertible)

[somejohn]

I'm talking about a high-pitched screatching/howling/groaning noise from the front of the car when pulling away in first gear from a stand-still.

I know that this has been covered a few times on this forum before (one guy had even uploaded a video although I can't find it now), but every time I've come across a thread discussing it, there wasn't any resolution and most were being fobbed off by their dealerships so I thought I'd share this for future reference.

The information I've managed to get from Mini today (after having had them look at my 2003 Cooper S many times in the past) is:

• It's a known and relatively common fault.
• The noise is your flywheel rubbing against the clutch due to a faulty clutch release.
• It effects only the Cooper S and Convertibles with GS6-85BG transmission.
• In the UK Mini Group TIC System it's under "UK-21-002-07 R52/R53 Cooper S GS6-85BG - Howling noise from transmission when first taking up drive."
• Unfortunately the only resolution is complete replacement of the clutch and assembly - if you're hearing this noise then both your clutch and flywheel are already being significantly damaged.

Official procedure calls for the replacement of:

• 21 20 7 548 804 - Modified dual-mass flywheel (ZMS);
• 11 22 7 560 579 x8 - Flywheel bolts;
• 21 20 7 520 449 x6 - Clutch torx bolts;
• 07 10 1 485 190 x2 - Gearbox dowels.

Depending on vehicle production date the clutch kit is different.
- Up to 07/04 Production:

• 21 20 7 551 383 - Clutch Kit (inc. release bearing);
• 23 11 7 551 719 - (only in conjunction with) Guide Tube.

- From 07/04 to 05/06 Production:

• 21 20 7 551 384 - Clutch Kit (inc. release bearing);
• 23 11 7 551 719 - (only in conjunction with) Guide Tube.

- From 05/06 Production:

• 21 20 7 551 384 - Clutch Kit (inc. release bearing).

If you chose to get this done at a main dealer, make sure you go with deep pockets, it's not a cheap fix!

If you leave it unattended it will eventually degenerate (as I've found) to a lot of juddering accompanying the howling noise and then a jerk as the howling stops and the car continues to accelerate. It's degenerated far enough for me that I'm getting it fixed.

Hope this information is useful for someone!