1st Gen R53 Cooper S Most liked posts in thread: Today's Job

Today's Job #7

My camera isn't working, so no photos of this Cooper job. I looked it over a couple weeks ago and filled a page with part numbers in preparation for its extended stay. When it arrived for service the customer commented on how the car was vibrating on the road; I already knew all the rubber mounts on the engine were torn or collapsed, so I was expecting something along that type of vibration. After driving about two hundred yards, I turned around expecting a wheel to fall off, it felt like riding an unbalanced washing machine. When I removed the right front tire, one section was parabolic shaped, another section flat on one side, another section was square, and the tread grooves snaked in curves, plus it had a sidewall bulge in one spot. I assume the tread separated and it would have soon peeled off.

This is an automatic BTW. I needed to replace the radiator support, among other things, with the front and airbox removed I could see dark purple stains over the gearbox and mount, at first I thought it was ATF, but then I saw tiny bubbles at the top of the transmission mount when I wiggled the engine. The transmission mount was cracked, allowing the mount bushing's hydraulic dampening fluid to escape. I didn't know until now that bushing was fluid filled. This engine has taken some whacks in its life, recent evidence looked like it had run over a cinder block, the deformed tire probably sent the mount over the edge.

 

The other auto-cross mod.




I think the housing is neat with the curved lines and seamless flare into the ring gear. Reminds me of classic space ships and early 20th century industrial machining.





With the smaller front sway bar and traction from both both wheels, this R56 can carve wicked tight turns; I can feel the onset of torque steer, but it's controllable.

 

Today's Job #10

Unlike the majority of R56 clutch failures I encounter, the flywheel in this case is not to blame. The secondary mass has little rock, radial movement is less than 20 degrees, and the springs & elastomers bounce back quickly. The clutch is still toast though.






The friction material is about as thin as poster paper on one side. Note the segmentation grooves are wiped out.




This R56 gets an OS Giken GTS clutch kit. I use a PVC coupler and 9/16 socket to align the disc.




The driver's side output shaft seal was leaking. The R56 seal is shaped differently than the R53, so I needed a different seal driver. I found a PVC fitting in the exact dimensions including a beveled angle to support the protective cover crown evenly.







This MINI must have spent a few years on the beach; fastener oxidation was extensive. Rust combined with excessive torque in the past made for tough disassembly.




The AC dryer was leaking dye colored PAG fluid. I hope the customer's warranty will cover this failure, because it will be pricey.