UPDATE: photos - Clubman Clutch Despair + waterpump to seal the deal

[MiniDeLux]

This is in reference to my post about the major problems I've been experiencing. I'm putting this up here in the hopes that someone can identify a similar problem early on and avoid the unpleasant and expensive situation I now find myself in.

Earlier this year I took my 2009 Clubman D (75,000km, 2 years old) to the dealership with a rattle from the clutch at idle (in neutral) when engaged (clutch out) that disappears when the clutch is disengaged (clutch in). This rattle/knocking noise began about 6 months ago and did not appear to get progressively worse over time. Occasionally, when starting the car there would be a "slapping" noise, that quickly damped out.

In any case, when I initially reported this problem, the dealership informed me it was "normal" and "not a problem". My warranty expired in July 2011. About a week ago, the clutch started slipping under high load in 4th gear. I initially noticed this when going up an incline and overtaking a transport truck. I immediately (same day) reported this to the dealership who informed me they couldn't service the car for another week as there were no free service appointments. I was subsequently obliged to drive the car with a slipping clutch for an additional 7 days. On top of the clutch problem, the water pump also went again a mere 3 months after replacement.

The car has been at the dealers since Monday morning. Yesterday, they informed me that the problems with the clutch/DMF are serious and both require replacement. I have not yet had the opportunity to speak with a mechanic, only a service representative, so I do not have an exact description of the problem yet. Nevertheless, I authorized the replacement at a cost to me of: €1980 before tax. The waterpump will be replaced under warranty.

Without my asking, the dealership also contacted BMW about a "goodwill" but BMW has refused to pay, citing the usual "driver wear and tear" and high mileage. I cannot dispute this more strongly, but that is currently where I stand with this situation. It is my opinion that there is a problem with the clutch/flywheel setup that the diesel models use. The dealers also provided me with a courtesy car at no cost.

In any event, I have asked the dealership to retain the damaged clutch and DMF so that I can inspect them myself. I intend to take pictures, if not to contest the BMW refusal of "goodwill", then to at least post them here in the hopes that this can help someone else avoid a similar situation. You may then pass judgement on my driving style if you so wish. I will be 100% transparent.

I will be updating this thread as the information comes in.

[MiniDeLux]

As promised, here are the photos of the clutch and DMF from my 2009 diesel Clubman. Clearly evident is the powdered friction material, blue-ing of the components and burn spots on, well, everything. Clutch parts also smelled "burnt". This comes at 75,000km on the clock.

Of course, all this gives the impression that I use the clutch to hold the car stationary on steep hills, launch the car aggressively from every stop light and use every spare minute of my day to race the car. However, none of the above is even close to the truth. I drive the car from my house to work every day - round trip of 71 kms. There are no stops, only roundabouts and highways. I drive calm enough to squeeze out 4.8L/100km in fuel efficiency from this engine. I am the sole driver of the car and only owner.

To me, this damage is incredible, it reeks of horrible abuse. I've been driving manuals for 23 years, of all marques. This is my first clutch problem. Ever.

After replacement, the car is completely quiet. No rattle, no clutch noise, nothing. Just an idling engine and, apparently, a turbo whine and water pump noise. The new clutch is not even remotely similar to the feel of the stock. Smooth pedal travel, bite point is reasonable. Old clutch had high bite point and was not butter smooth.

Ongoing problems mean the car has to go back unfortunately, since the water pump needs changing and the turbocharger is filthy dirty and whining, which makes me suspect the wastegate isn't functioning properly and/or something else.

I'm really, really, really, really fed up with this car.