R56 Engine replaced; now destroys drive shafts! - MINI Cooper Forum

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post #1 of 6 (permalink) Old Jun 26th, 2014, 11:28 PM Thread Starter
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R56 Engine replaced; now destroys drive shafts!

My son's R56 Cooper S recently had a rebuilt engine dropped in to replace the original which was "broken".
Within an hour or so after collecting the car from the garage, the outer CV joint on the front left drive shaft fell to bits.
A new drive shaft was installed and all seemed fine. Until he had driven the car for about 5 miles. The brand new drive shaft went bad, just like the original.
It seems the drive shaft may have too much slack, allowing the CV joint to part when cornering, tearing up the rubber boot that covers the joint and allowing the bearings to thrash around.
Looking at the engine mounts from above, there is a mount on the left side of the car that can be easily seen. The mounting bolt on that side comes up through a slot in the mount, allowing for sideways movement of the engine in the mount.
The bolt has been installed and tightened with the engine apparently all the way over to the right side of the car, ie the mounting bolt is hard up against one end of the slot in the mount.
It looks very much as if the engine has been mounted way over to the right side of the car which means the transmission is too far away from the wheel and the drive shaft is effectively too short.
Is there a correct way to align the engine left to right? Does the engine have to come to bits to properly align the engine so the engine is centred properly between drive shafts, or is it correct to slacken that one slotted engine mount and lever the engine into the correct alignment before tightening again?
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post #2 of 6 (permalink) Old Jun 27th, 2014, 12:20 PM
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it's not possible to mount the engine too far over, the mount on the drivers side top is hard up against the side of the engine bay and on top of the chassis rail below.
the passenger side mount also has no adjustment, then there is a third mount at the bottom with a huge mount that can only fit one way.

either they are fitting incorrect driveshafts (many different gearboxes and shafts for r56) or they aren't careful enough when fitting them and the cv bearings are popping out of the joint and then destroying it.
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post #3 of 6 (permalink) Old Jun 27th, 2014, 02:28 PM Thread Starter
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Well that's a bit baffling.
The mount on the passenger side has an elliptical slot, not a round hole and there is about an inch of possible movement along that slot.
The first drive shaft popped and destroyed the CV joint was the original and the replacement that lasted 5 miles was the correct replacement.
How can you fit the drive shaft incorrectly? Surely it goes into the gearbox end until the O ring pops into place, then the other end goes into the hub and the nut tightened accordingly?
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post #4 of 6 (permalink) Old Jun 28th, 2014, 09:56 AM
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ahh ok sorry there is some adjustment in the central bolt of the top mounts, I'm surprised it would be out to one side though because the bottom mount has no adjustment.
Check the left side mount where it is bolted to the body with 13mm bolts, sometimes they can come loose and give a lot of movement.
if the joint is put on a weird angle during installation or hyper extended the little needle bearings can fall out of place and cause a world of pain.
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post #5 of 6 (permalink) Old Jun 28th, 2014, 01:33 PM Thread Starter
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Thanks for the info.
It looks like it has now been cracked. The bracket is referred to in the manuals as the transmission bearing or suspension bracket (fair enough as it connects to the diff). Having removed the ECU and various other bits, it became obvious the bolt was not in the original location as it was possible to see marks from the original installation, about 1/2" away. Once the nut was loosened, it was possible to crowbar the engine over to the left until everything was back where it used to be. Next step will be to replace the drive shaft and check the slack in the shaft with the wheel turned full lock to the left. With a bit of luck, it shold stay in one piece!
Cheers
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post #6 of 6 (permalink) Old Jun 30th, 2014, 11:26 AM
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good stuff mate, I've never seen one come off completely like yours had but I've seen a couple where those mount bolts have started to come loose.
no more cv's!
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