Cooper S ticking noise

[94SwiftGT]

Sorry, this is long.

Well, I unfortunately have this dreaded knocking noise. I can repete it at will at any time. It is so bad that I have been forced to drive with the passenger window up.
I have had a MINI service nightmare trying to get this taken care of, or even taken seriously by mini service personnel. It has gotten to the point that I am ready to just selling my S as I expect the bottom to fall out at any moment.

I have take my car to the service department 3 times to have this looked into. I have driven 8 different mini personnel in my car, and they all agree that they can clearly hear the noise coming from the engine.

Visit #1: I was just brushed off, and I was told that the noise is a normal noise for an S. They were also unable to reproduce the noise, even thou I had provided them with a complete step by step procedure.

Visit #2: The noise has gotten worse. Took the service forman for a test drive, and he heard the noise, but felt it was an exhaust leak. He told me that he would exchange my aftermarket exhaust for a factory exhaust to determine if it was an exhaust leak. After 4 days I called the service dept to see how my car was doing. After some delay I was told my car was ready to pick-up. The service ticket said noise appears to be exhaust leak.
I found out later that they never exchanged the exhaust, and that my car just basically sat at the dealers.

Visit #3:The exhaust was finally changed and I went to test drive with factory exhaust in place, and the noise was easily heard. It actually seemed louder with the stock exhaust. I was told that an appointment was being set up with the feild service rep (FSR), but that I would have to pick-up my car until the appointment could be arranged. I told the service manager that I was uncomfortable driving my car with this hammering coming from the engine. I picked my car up as ordered, and I again expressed my concern to the service manager. The service manager said he would contact me as soon as the FSR gave him his schedule.

After a week I hadn't heared anything so I contacting the service manager again to see when I could expect the FSR to look into my problem. After a couple of days I finally heared from the service manager, and he said that he had driven a couple of other S's that made the same noise. He said that the noise is normal for an S, and there was nothing more they could do. I told him that this was unacceptable, and I wanted an appointment with the FSR, and he agreed to arrange an appointment with the FSR.

I am now going to wait another week before hopefully getting this problem looked at with any hope of a resolution.

This whole situation has really made me question my continued ownership of a Mini/BMW product.

I really love my car, but these service issues have really tarnished the whole experience.

Again sorry for the long post, but I felt others should be made aware.

03DrkSlvrS

[roland2003]

Hi Guys,
Ok there are two totally different ticking faults on the same thread.If it only does it when moving under load it is either pinking as described on my last post or blowing exhaust manifold gasket,generally worse from cold.
If noise occurs reving in neutral (and is not affected by pressing the clutch pedal) as has been mentioned is probably related to the pulley system.To prove remove the belt and start engine if it is this the noise will go.WARNING run engine for max one minute as no water pump and engine will over heat if left much longer!!!! Do not leave running you will blow the headgasket for sure!
If the goes it could well be a burr or high spot on one of any of the pulleys.Inspect all the way around very carefully.As the crank pulley is mounted on rubber if the rubber distorts it could be running eccentricly 'picking up on the belt slightly each rotation'.
Good luck!

Regards Roland GT Tuning

[here2help]

On my past experiances it has been the clutch release bearing that causes the rattling noise whilst driving which goes when the clutch is depressed.

Also try the heat shelids has they do creak/rattle when warm.

One other thing i have come across loads of times is the power steering pipe knocks/rattles against the oil cooler pipes.(Only cooper s's)

[94SwiftGT]

I've had the throw-out bearing replaced a few months ago, but that noise seemed more like a rubbing or scraping noise.

The knocking that I am cursed with is the knocking/hammering that seems to start at around 3000 rpm and continues until the wind noise masks the noise.

The knocking/hammering happens whenever accelerating at anything above a walking pace. The noise is much more noticeable when driven along any object on the passenger side of the car.

The knocking/hammering sounds like a rod knock. This is why I am so concerned, as if a rod breaks I may be placed in extreme danger.

The service personnel that I have been deaing with don't seem to take my concerns seriously at all. The service personel don't have any idea what is causing the noise, but they don't think it is of any concern.

I really wish that Mini would take care of this so I can feel secure driving my car again.

The noise is definitely not a heat shield, as it is a hammering noise not a rattling. The service guys tried this excuse already.

03DrkSlvrS

[MattiCooperS]

Not good news - finally got my car back after going in for two days i get it back 6 days later.

they say the noise is within the charger and are unwilling to replace it unless the ticking gets worse or something fails - however i've driven it tonight and the ticking is quieter so i dunno what to do?

guess i'll have to monitor it and see what happens.

Matti

[sholto]

Keep hassling them. It's a known problem. Ring BMW (MINI) head office and complain. I had my state BMW warranty rep come out to here my ticking noise and they are finally going to fix it after two years of complaining. It is the harmonic balancer. They have a new one that APPARENTLY fixes the problem.

Good luck

[94SwiftGT]

Matti,

I agree with sholto keep after them. I wouldn't waste the time with the local service dept. Call directly to Miniusa. Keep pushing the issue with Miniusa until they make it right.

Give them all the details and express how disappointed you are with the situation.

We shouldn't be forced to wait for something to fail before something is done. There appears to be enough cases that they should have a solution that doesn't leave us (their customers) holding the bag.

Shokto, have you had the hormonic damper replaced? Are you sure that that will fix the problem? Are you worried about the long-term effects of the hormonic damper being bad for so long? Couldn't the hormonic damper being bad cause future long-term crankshaft problems?

Keep the rest of us posted on how things are going. We need to support each other in our efforts to have Mini take care of this problems.

03DrkSlvrS

[AndrewH]

Quote: Originally Posted by 94SwiftGT

Matti,

Shokto, have you had the hormonic damper replaced? Are you sure that that will fix the problem? Are you worried about the long-term effects of the hormonic damper being bad for so long? Couldn't the hormonic damper being bad cause future long-term crankshaft problems?

Keep the rest of us posted on how things are going. We need to support each other in our efforts to have Mini take care of this problems.

03DrkSlvrS

I keep having visions of bearings cutting out in the alternator/supercharger/drive shaft etc as I've seen what happens when you have incorrect tension on a drive belt. After stressing these concerns to my service manager, he said that the national BMW tech rep had assured him that the problem with the damper would have absolutely no negative effect on any of the other components connected to the drive belt. I really don't know what to think. It's hard to sort the BS from the facts.

Shokto, let us know if and when yours is fixed as I was told the new part would be available in Australia in less than 2 months about a month ago.

Cheers

Andrew

[Steeljacket]

Hi, mine and my wifes S's also has the RHS clicking noise, I have not read all the posts here and appologise if someone has already mentioned this.

The problem is on the S only, not the Cooper or One, the engines are basically the same so I see it can only really be down to charger, gearbox or cam belt pulley system. My bet is the charger. It needs a process of elimination, what is different on the S to Cooper and then what is on the right hand side of the car and not the left.

I am still clueless as I am not a mechanic so any help would be appreciated and if anyone gets it fixed

[sholto]

It was around 2months ago when the warranty guy came and agreed that there was a problem. I went to the dealer today and they said they didn't know when the new part would arrive. It's going in next week for new brake pads so I'll get the warranty guys number and ring him directly. Keep you posted.

Cheers Sholto.

[sholto]

Quote: Originally Posted by roland2003

Hi Guys,
Ok there are two totally different ticking faults on the same thread.If it only does it when moving under load it is either pinking as described on my last post or blowing exhaust manifold gasket,generally worse from cold.
If noise occurs reving in neutral (and is not affected by pressing the clutch pedal) as has been mentioned is probably related to the pulley system.To prove remove the belt and start engine if it is this the noise will go.WARNING run engine for max one minute as no water pump and engine will over heat if left much longer!!!! Do not leave running you will blow the headgasket for sure!
If the goes it could well be a burr or high spot on one of any of the pulleys.Inspect all the way around very carefully.As the crank pulley is mounted on rubber if the rubber distorts it could be running eccentricly 'picking up on the belt slightly each rotation'.
Good luck!

Regards Roland GT Tuning

It is definately not pinging (tried octain boost etc). The warranty rep came and inspected my car and they are replacing the harmonic balancer with a new modified one. Apparently there is some misalignment.... I've been waiting 2 months, so I'll have to give him call to see when the part arrives, cause the noise sounds dreadful!

Cheers Sholto

[MattiCooperS]

Well i've written a full A4 letter to Mini UK after sending an email to my UK site.
i'm going on holiday for a week without the car so I hope I come home to a reply...

Matti

[roland2003]

Hi guys,I know you shouldn't have to ,but sometimes it's easier to try &sort it yourself. Take the belt off.Inspect the belt for damage.Check for damage all the way Around the pulleys.Spin the pulleys,are there any tight spots through rotation ?(especially the S/c) Get an engineer friend to 'clock' the crank pulley with a DTI to establish any runout.Run the engine without belt very briefly ONE MINUTE MAX!!!), Doe's the noise go ? No one wants the noise to go more than you therefore with a little work &time you are one who can solve it quickest,and you may even live a little longer to boot!

[Robot Features]

Hey Restyle

Been offline for a couple pf weeks, sorry for late reply.

I will post up some pics when i take some decent shots. Thanks for the tips on how to upload.

Hey guys do you think the new model Cooper S "phase 2" will have the same probs we're all having?? I'm 100% definite that mine is related to clutch pedal. If i press pedal, the tapping/knocking sound goes away. Very weird!

Regards

Mic

[GMINI]

Quickly: responding blindly to a six page thread- suspect the drive axle for your click source. That was my momentum clicking cause. A click after shifting gears at the onset, and ultimately maybe two three or four clicks after shifting gears - and yes that is when load is applied.

Best wishes