1st Gen R53 Cooper S Most liked posts in thread: Funny clutch noise

What you're describing is the classic "Chewbacca" noise, search for that term on any MINI forum and you'll find scads of threads on it.

The only fix is to replace the clutch and flywheel, but it's not hurting anything, it's just annoying. What's making the noise is your dual mass flywheel.

There is a Valeo clutch kit available now that uses a regular flywheel, disc and diaphragm clutch cover that will replace the OEM for about half cost and it will cure the problem forever. I just installed one last week and the owner is absolutely thrilled with it, just FYI.

He got his from Way Motor Works

 

Nick, does it sound like a throwout bearing? My R53 throwout bearing was a little noisy when cold from the day I bought it until the day I sold it 106K miles later.

 

^^^^^ +1, what Mark said. My '04 did the same thing, however not sure if they changed anything in the '05+ newer transmission.

 

If the noise comes when the car is out of gear, you're fine. If it makes the noise when in gear, not so much. At a stop light, if you let out the clutch and it's out of gear and you hear a clattering, that's a jammed dual-mass flywheel, and you just have to live with it, unless you have $2k you want to throw at the problem. If the sound happens while driving in gear, start saving, because your TO bearing is about to scatter inside your bell housing and leave you dead in the water.

 

my '06 S has had a little hoot or moan when it is cold and i start letting out the clutch, going on 5 years now.

 

The Valeo seems to be a good choice, again the owner of the one I replaced loves it, he refers to it as his "Honda" clutch, and he means that in the best way! Smooth, engages mid stroke, and always the same, light and very positive. He also says he noticed no additional vibration from not having the dual mass flywheel.

He also says the flywheel's lighter and the engine seems to rev more willingly, but it does not impact starting from a stop or anything. Add in half the cost of a factory clutch and it seems win/win to me. Of course, the labor cost is the same...so it's still an expensive clutch to replace.

 

My 05 first did that one morning last year in Robbinsville, it was a damp morning and I just attributed it to the morning moisture, well it continues even now. It only does it when car is cold and only first gear, after two or three starts it is gone.
Guess I better start saving.