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Discussion Starter #1
I have a Cooper picked up January 19th 2004 - 53 Plate.
Currently it has 21.6K miles.

Mods: Pipercross Viper Induction Kit, PlayMINI Cat Back Exhaust, JCW Strut Brace and MTH ECU Remap.

About a week ago, I noticed a slight oddness about 2nd gear. The engine noise seemed a little raspy. Throughout the week, the problem has got worse and worse.

1st seems fine. However in 2nd, up to 5th, when I'm accelerating or slowing down with a small bit of engine braking, I get a rather bad sound. It sounds quite high pitched, a little gargly (like a small dog growling :eek:) and raspy.

My initial thoughts were possibly Induction, loose bolts on it or the Exhaust. So I did some testing.

The sound
ONLY occurs in 2nd, 3rd, 4th and 5th.
ONLY Occurs during acceleration or if slowing down whilst IN gear using engine braking (Nothing violent)

It doesn't occur if in cruise control and the car isn't accelerating OR when I'm cruising by gently holding the gas pedal in position.

It does NOT occur when the car is at a standstill in Neutral just idling. Nor does it occur if I blip the engine revs up to 2.5 - 3.5 K (Haven't gone any higher for obvious reasons). Similarly it doesn't occur if I am in a gear but the clutch is depressed effectively putting the car into neutral.

So, in conclusion, I don't think it can be the mods simply because surely the noise would occur when the engine is revved in neutral. The sound ONLY occurs when the car is actually IN a Gear above 2nd and is USING that gear... This makes me think Gear Box issue (knowing the history of Gear boxes and MINI). #

Gear shifting is smooth with the exception of coming down into 2nd from 5, 4 or 3 sometimes causes it to crunch and that has only started very recently.

My cousin who is a mechanic thinks there's a possibility that the Gear Box oil is very low. Another M2 Member also suggested Gear Box oil. My car has recently had it's 2nd TLC service so the engine oil is still golden and well at the level.

Heh, I thought THAT oil serviced all parts... (I'm not an expert :))

What are others thoughts?

The car IS booked in for Tuesday but it would be nice to know opinions :)
 

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I have noticed the same noise in my car recently. I did some research, namely on northamericanmotoring.com, and found it looks like a problem with the car. Several complain about it. I haven't found a definitive answer as to the problem. Others have had everything from wheel bearings to half-shafts to entire transmissions because of it. Keep everyone updated if you find a solutions.
 

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Discussion Starter #3
Thanks for the reply, could you post a link to the threads in NAM.com

I'll definately keep people updated.
 

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Discussion Starter #5
Well, I spoke with BMW and Apparantly, I have a new Gearbox and Clutch !!! I would have had the car back today had a Gear Selector cable not seized.
Should have it back tomorrow... :)
 

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Discussion Starter #7
My Car is driving like an ABSOLUTE DREAM ! It'slike I've just picked up a brand new car... the car is MORE responsive, is quick off the mark unlike the last time when it would stumble, pick up, stumble and then maybe go...

The whole car seems a lot tighter in the way it drives, shifting is beautiful.

PLUS, the car sounds even louder now.. I mean regards to the Viper induction and PlayMINI exhaust.. the engine note is gorgeous...

When they replace the gearbox, they literally have to strip out the entire front end so everything is all put back in nice and tight and tuned up.

Fantastic !!! Very pleased with the results.

Those of you with Gearbox problems, if you're in the USA in particular, do not let your dealer screw you over... I've heard way too many horror stories about them on these forums.

The gearbox in the 04 MINI (and prior) DOES have a problem..it's known and they should fix it under warranty with NO charge at all. Mine was done ALL under warranty.

And of course, the car came back spotless inside and out.. :)
 
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