2006 MINI Cooper S 2002-05 CLUTCHES Bleeding, Removal & Installation
2002-05 CLUTCHES Bleeding, Removal & Installation
APPLICATION MANUAL TRANSMISSION APPLICATIONS MINI Designation GS5-65BH GS6-85DG
Transmission Model Midland R65 Getrag G285D
DESCRIPTION There are two types of clutch assemblies used on the MINI. The MINI Cooper uses a conventional type clutch and flywheel arrangement. The MINI Cooper S has an upgraded clutch in combination with a dual mass flywheel. For information on Cooper S clutches, see CLUTCHES - COOPER S article. The MINI Cooper clutch system consists of the following components:
Pressure Plate Clutch Disc Clutch Release Bearing
CLUTCH HYDRAULIC SYSTEM PRESSURE PLATE The MINI Cooper pressure plate is constructed from steel. The pressure plate is located on the flywheel by 3 dowels and retained by 6 external Torx headed bolt. CLUTCH DISC The clutch disc is constructed from steel and incorporates four double springs to absorb torsional vibration and has a friction surface on each side. The 200 mm diameter clutch disc is marked to indicate the direction of mounting. CLUTCH HYDRAULIC SYSTEM The master cylinder is located on the pedal box and is supported by 2 mounting points. The lines, which connect into the clutch slave and master cylinders, are quick release connectors. The brake master cylinder reservoir supplies fluid to the clutch master cylinder. The slave cylinder is the same on all models, although the location is different. MINI Cooper slave cylinder is located on top of the gearbox, in front of the battery box. All slave cylinders are mounted with 2 bolts and have provisions for bleeding.
BLEEDING NOTE:
Numbers in text refer to numbers in figures.
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2006 MINI Cooper S 2002-05 CLUTCHES Bleeding, Removal & Installation
Remove dust cap from bleeder screw. Connect pressure venting unit to bleeder screw (1). See Fig. 1. Attach special tool (21 5 030) to clutch slave cylinder. Open bleed screw, ensuring opening pressure does not exceed 1 bar. Close bleeder screw when no further air bubbles emerge. Otherwise repeat the procedure. Correct fluid level in brake fluid reservoir. See Fig. 2.
Fig. 1: Connecting Pressure Venting Unit To Bleeder Screw Courtesy of BMW OF NORTH AMERICA, INC.
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2006 MINI Cooper S 2002-05 CLUTCHES Bleeding, Removal & Installation
Fig. 2: Bleeding Clutch Hydraulic System Courtesy of BMW OF NORTH AMERICA, INC.
ADJUSTMENTS CLUTCH PEDAL Clutch pedal stroke and free play are adjusted automatically.
REMOVAL & INSTALLATION CLUTCH NOTE:
Numbers in text refer to numbers in figures.
Removal & Installation Microsoft Tuesday, February 16, 2010 10:29:50 AM
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2006 MINI Cooper S 2002-05 CLUTCHES Bleeding, Removal & Installation
Remove transmission. See MANUAL TRANSMISSION article. Block crankshaft pulley with special tools (11 2 150) and (11 8 320). See Fig. 3. Slacken pressure plate screws (1-6) uniformly. See Fig. 4. Unscrew all mounting bolts. Remove pressure plate and clutch plate. Clean flywheel and check for wear and damage. If necessary, replace flywheel. Check clutch plate for damage and friction rust, replace if necessary. Replace contaminated clutch plate (oil, cleaning agent, etc.). Note direction marking GEARBOX SIDE (1) for transmission side of clutch plate. See Fig. 5. Check clutch disk for wear. Measure lining protrusion on transmission side. Measure from rivet head (1). The clutch plate must be replaced if the lining clearance at the rivet head (1) is less than 1 mm. See Fig. 6. Mount clutch plate on transmission input shaft and check for ease of movement. See Fig. 7. Install pressure plate and clutch plate with special tool (21 6 100). See Fig. 8. Replace screws of pressure plate and tighten down in sequence (1-6). See Fig. 9. During installation, turn centering mandrel (21 2 260) outwards in stages when tightening down pressure plate. Pressure plates must not touch centering mandrel. Note that during installation, turn special tool (21 6 100) when tightening down the pressure plate in order to center the clutch plate better.
Fig. 3: Blocking Crankshaft Pulley Courtesy of BMW OF NORTH AMERICA, INC. Microsoft Tuesday, February 16, 2010 10:29:50 AM
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2006 MINI Cooper S 2002-05 CLUTCHES Bleeding, Removal & Installation
Fig. 4: Loosening Pressure Plate Screws Courtesy of BMW OF NORTH AMERICA, INC.
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2006 MINI Cooper S 2002-05 CLUTCHES Bleeding, Removal & Installation
Fig. 5: Direction Marking GEARBOX SIDE Courtesy of BMW OF NORTH AMERICA, INC.
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2006 MINI Cooper S 2002-05 CLUTCHES Bleeding, Removal & Installation
Fig. 6: Measuring From Rivet Head Courtesy of BMW OF NORTH AMERICA, INC.
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2006 MINI Cooper S 2002-05 CLUTCHES Bleeding, Removal & Installation
Fig. 7: Mounting Clutch Plate On Transmission Input Shaft Courtesy of BMW OF NORTH AMERICA, INC.
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2006 MINI Cooper S 2002-05 CLUTCHES Bleeding, Removal & Installation
Fig. 8: Installing Pressure Plate & Clutch Plate Courtesy of BMW OF NORTH AMERICA, INC.
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2006 MINI Cooper S 2002-05 CLUTCHES Bleeding, Removal & Installation
Fig. 9: Pressure Plate Screw Tightening Sequence Courtesy of BMW OF NORTH AMERICA, INC. CLUTCH SLAVE CYLINDER NOTE:
Numbers in text refer to numbers in figures.
Removal & Installation
Remove battery container. Do not clamp inlet line of clutch slave cylinder. Remove retaining screws (1) of clutch slave cylinder and remove clutch slave cylinder (2). Release retaining clip (3). Disconnect line (4). See Fig. 10. After work is completed, bleed clutch hydraulic system. See BLEEDING.
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2006 MINI Cooper S 2002-05 CLUTCHES Bleeding, Removal & Installation
Fig. 10: Removing Clutch Slave Cylinder Courtesy of BMW OF NORTH AMERICA, INC. CLUTCH MASTER CYLINDER NOTE:
Numbers in text refer to numbers in figures.
Removal & Installation
Remove/lower brake fluid level to the underside of the clutch master cylinder feed pipe (1). See Fig. 11. Remove driver side storage tray. Remove pin (1) from clutch pedal. Remove clutch master cylinder retaining bolts (2) and remove clutch outlet pipe (3). See Fig. 12. Lower clutch master cylinder sufficiently to remove inlet pipe (1) and remove clutch master cylinder (2). See Fig. 13. Bleed clutch. Note that clutch master cylinder feed pipe contains a sealing ring which may detach when removing feed pipe. Reinstall sealing ring into clutch feed pipe prior to refitting pipe.
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2006 MINI Cooper S 2002-05 CLUTCHES Bleeding, Removal & Installation
Fig. 11: Lowering Fluid Level To Underside Of Clutch Master Cylinder Feed Pipe Courtesy of BMW OF NORTH AMERICA, INC.
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2006 MINI Cooper S 2002-05 CLUTCHES Bleeding, Removal & Installation
Fig. 12: Removing Clutch Master Cylinder Bolts & Removing Clutch Outlet Pipe Courtesy of BMW OF NORTH AMERICA, INC.
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2006 MINI Cooper S 2002-05 CLUTCHES Bleeding, Removal & Installation
Fig. 13: Removing Clutch Master Cylinder Courtesy of BMW OF NORTH AMERICA, INC.
TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Application Clutch To Flywheel Slave Cylinder To Bracket
Ft. Lbs. (N.m) 15 (20) 18 (24)
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