This is the second part in replacing the clutch on my 2003 Mini Cooper S. At the end of the 1st part & YouTube video, I was stuck on the top bolt which is holding the ‘octopus’ connector on.
After borrowing some slightly smaller sockets, along with completely removing the starter motor, I was able to get enough slack on the cables to make enough room to get the socket on and bolt out. After removing the remaining 6 bell housing bolts and the gearbox mount the gearbox was wiggled out.
It hasn’t been plain sailing getting to this point. The bolts that hold the clutch slave cylinder in place have snapped and now need extracting, to get the slave cylinder off I have had to cut one of the lugs off so that needs replacement.
Once again, I am stuck. I now need the E8 reverse Torx adapters so that I can remove the pressure plate. The reverse Torx are also used on the steering rack, so it would be worth getting a set of these going forward. Thanks to a next day delivery on Prime, I received the E-Torx adapters. First time doing these bolts and I was a little nervous, but my trusty little ratchet got the bolts off.
With the rivets starting to wear, the flywheel has similar wear marks on it, it’s safe to say that the clutch did need replacing. Below is a video from when I got stuck to when I finally got the clutch off.
Status update
If you watch the videos that accompany this series, you’ll realise that this job has spidered from replacing the clutch to more of a full refresh. A list of jobs that need tackling are as follows:
- Rocker cover bolts – disintegrated
- Clutch slave cylinder bolts – stuck in gearbox casing after snapping
- Clean engine and gearbox
- Leaky mini kit
- Supercharger service
- Dipstick
- Clutch, flywheel and rear main seal
- Clutch slave cylinder
- CV joint boots need replacing
- Track rod end
- Exhaust
- Various bodywork fixings (wheel arch liner, bumper bolts/clips etc)
- Radio
- Drivers door card fitting and investigate window
What’s next?
Well, I have a couple of days where I won’t be able to work on the car due to other commitments. I have to order a few bits of equipment (engine crane, belt tension remover, something to extract bolts). I will also have to order parts. As a result, there will be a small delay on any updates. That being said, I will do what I can and in the mean time, please like/follow/subscribe on Social Media, the links at the top as this will help grow the project.