Engine Drivetrain 1st Gen Cooper S 03 Clutch Replacement Issues

Discussion in 'Tuning and Performance' started by xsmini, Apr 16, 2016.

  1. xsmini

    xsmini Member

    May 27, 2009
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    I'm looking for a little help. I just finished rebuilding my 03 s with just a little over 365,000 miles. Good news, got it all back together and it fired right up. Since I had the engine out I decided to replace the original clutch, pressure plate, dual mass flywheel, throw out bearing, and guide. Now the part I can't figure out. The throw out bearing comes into contact with the pressure plate splines after about a 1/2" of travel, thus the slave cylinder does not have enough travel to fully release the clutch. I dropped the engine again figuring I had missed something, I cannot find anything not put together correctly. Any suggestions would be appreciated. Thanks,

    Nik
     
  2. BlimeyCabrio

    BlimeyCabrio Oscar Goldman of MINIs
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    May 4, 2009
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    Pics might help
     
  3. xsmini

    xsmini Member

    May 27, 2009
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    Photos to explained

    [​IMG]


    Shifter arm where throw out bearing should be in contact w/ pressure plate splines


    [​IMG]


    Shifter arm where throw out bearing comes in contact w/ pressure plate splines...
     
  4. BlimeyCabrio

    BlimeyCabrio Oscar Goldman of MINIs
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    That part I understand. I meant pics of the interior of clutch / guide tube / throwout bearing / flywheel / etc. would probably be helpful to diagnose.
     
  5. BlimeyCabrio

    BlimeyCabrio Oscar Goldman of MINIs
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    Just checking... which side of the slave cylinder mount are you installing the slave on... If you install the slave wrong, it will have this same symptom...
     
  6. xsmini

    xsmini Member

    May 27, 2009
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    I'll get pics of the inside tonight. I didn't snap any when it was apart last time. The slave is installed correctly. I did think of that :)

    Nik
     
  7. MCS02

    MCS02 Moderator
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    Jul 31, 2009
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    Do you have the throw out bearing installed in the correct direction.
     
  8. xsmini

    xsmini Member

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    Haha, yes, yes I do
     
  9. MCS02

    MCS02 Moderator
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    Sorry I had to ask. Believe it or not I have seen it done on a different brand car.
     
  10. xsmini

    xsmini Member

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    No worries, glad you did.
     
  11. xsmini

    xsmini Member

    May 27, 2009
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    Still haven't figured out the clutch issue. Here are some photos of the inside.


    [​IMG]


    Flywheel, clutch and pressure plate all put together.


    [​IMG]


    Point where throw out bearing should come in contact with pressure plate


    [​IMG]


    Point where throw out bearing actually comes in contact with pressure plate
     
  12. jasonsmf

    jasonsmf Active Member

    Jun 12, 2009
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    Have you double checked the bolt that attaches the yoke to the shaft? If that's sheared off internally, it might cause this problem.

    Jason
     

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