Mini 2 Gearbox Repair Manual
MINI Cooper Transmission Problems The MINI 5-speed gearbox GS5-65BH found in the Cooper models (non-S) built between 2001 and July 2004 is commonly referred to as the R65. The front mounted transverse configuration was a major design challenge when it came to the length of the engine/gearbox unit. In designing the MINI, maximum crash safety and therefore optimum configuration of the longitudinal members in the engine compartment and front body section were priorities. This requirement imposed an additional limit on the permitted length of the engine/gearbox assembly.
Because the length of the engine is largely fixed, depending on the spacing between the cylinders, the length restriction on the powertrain as a whole determines the length available for the gearbox. There was therefore no room in the MINI’s engine compartment for a conventional two-shaft gearbox with all the gears arranged one behind the other. BMW had wanted the car to have a Getrag gearbox, but the original UK engineers put in the instead, because it was $170/car cheaper, more compact with a two-shaft as opposed to a three-shaft layout, and no inherent cyclic vibrations, so a mass damper was not needed. The R65 was an existing major component, which was already being manufactured on the Longbridge site, and was in large scale use in other Rover Group front-wheel-drive cars.
Originally a PSA (Peugoet-Citroen) design, it was well-proven, and well thought of. Chris Lee (MINI Product Leader '96-'99) and his team stuck to their convictions, produced rafts of evidence regarding costs, performance and service experience. Back-to-back tests, evaluations on the road and comparisons of torque capacities were all made. In addition, major improvements to the R65's change quality, a reduction of free play and healthy attention to warranty claim records were all needed before Rover’s R65 won the argument. Although not widespread, there have been numerous reports of failures with the R65 Midlands gearbox over the years.
Compounded with MINI USA’s policy to replace instead of repairing these gearboxes with factory rebuilt units, the owners are faced with hefty repair bills from their local MINI service centers. Fortunately, replacement parts are available for the R65 Midlands gearbox from suppliers such as Mini Mania Inc. Qualified independent transmission repair shops are able to repair these gearboxes at a fraction of the cost of replacing the entire gearbox. Sources: MTZ worldwide 7-8/2002 Volume 63 Motoringfile: The Origins of the MINI Cooper 5-speed Manual, Aug 24, 2003 Additional Information: Occasionally, the Midlands Gearbox suffers from bearing failure on both the and secondary shaft pinion bearing, the input bearing failure would give a noise at idle in neutral as well as while driving with the noise reducing as higher gears were selected. The failure gives no noise at idle but an increasing noise in line with road speed as the vehicle increases speed. Both these faults are repairable at minimal expense if caught early; however, if they are left to develop then both can cause a complete gearbox failure.
Mini 2 Gearbox Repair Manual
The other main cause of failure in this gearbox is “planetary gear” failure. The “” are located inside the differential and over time they become worn and damaged, leading to a break up of individual gears, this is often not spotted until it is too late and very often results in a complete failure of the gearbox usually with case damage to the diff area. The early signs to look for regarding this fault would be excessive slap or a knock on take up of the clutch bite.
Often the first sign of any damage is a noise in the gearbox rather like an ice lolly stick in a bicycle spoke. Unfortunately this normally indicates a gearbox failure beyond repair and would require a. Total gearbox and clutch failure amid heavy traffic.Car began to shake violently.I had kids in the car and a major accident narrowly avoided.The gearbox failed without warning.I am not a mechanic and would not have spotted signs anyway.
The way BMW Mini UK complaints department have behaved regarding this matter is shocking.A reconditioned gearbox and new clutch took every penny I had. When BMW Mini became aware that there was a problem with the R65 gearbox they stopped using them and put in a German Getrag 5 gearbox. However, with great skill to cancel any likely costs to themselves.I note no recal was ever made.BMW Mini declared.Any complaints or problems surfaced or queried regarding the R65 gearbox had to be dealt with through a Mini UK Dealership. But.Mini UK policy of replacing these faulty gearbox meant they had to be shipped from the factory.The owners consequently were faced with hefty repair bills from their local Mini service centre.
This is absolutely shocking behaviour.I will not purchase another Mini EVER.they obviously feel that customers are brainless morons to be manipulated. I was looking for information on rebuilding the Midland 5 speed and you have a kit to facilitate this, but according to your article, 'Often the first sign of any damage is a noise in the gearbox rather like an ice lolly stick in a bicycle spoke. Unfortunately this normally indicates a gearbox failure beyond repair and would require a replacement gearbox.' I just want to make sure that when you say this symptom would require a 'replacement gearbox', that rebuilding the original with your kit would be sufficient or will I have to scrap and replace in it's entirity.
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Our mechanics are able to carry out logbook servicing, according to the manufacturer’s specifications, using quality parts and lubricants. The mechanic will sign off each item and stamp your logbook once all tasks are completed and your manufacturer's warranty will remain intact. You sure can! Once you have entered in your vehicle details and location on the home screen, the next page will ask you what repair or service you're after. You can browse through the categories that we've listed, such as Brakes, Clutch or Timing belt/chain, or by clicking the blue 'Search repairs & inspections'button at the bottom of the page, you can search for the repair you're after.
If you're still unable to find what you're after, click on the blue 'Can't find it? We can help!' Button and you'll be provided with a comment box where you can describe the repair you need. Once you've selected a repair, either click 'Continue' to move on in the quote process or, If you'd like to add another repair, click the 'Add more items' button.
How Much is a Transmission Repair or Replacement? The cost of carrying out transmission repairs or replacement varies between make and model.
With basic repairs costing between $200 up to $500+ and extensive repairs costing anywhere between $1000 up to $5000+, especially if the transmission requires complete overhaul or replacement. The transmission fitted to your vehicle is what transmits drive, from the engine to the wheels.
Falk Gearbox Repair Manuals
These transmissions can come in many forms, including;. Manual. Automatic. Semi-Automatic. Constantly Variable. Dual-clutch Although configurations vary, they are all designed to carry out the same job and all require periodic maintenance to continue operating at their best. All transmissions are filled with certain types of transmission fluid which provides lubrication and cooling of the transmission.
In the case of automatic transmissions, the fluid also provides hydraulic pressure to select the proper gear. Carrying out maintenance on a vehicle equipped with a manual transmission is as simple as changing the oil in the gearbox as there is no filter to capture particles and debris. In an Automatic transmission however, there will be a filter located in the transmission pan. This filter will be attached to the transmission oil pump and will remove any debris or particles to allow for proper transmission operation. If not changed, these particles will cause premature wear and failure of components. Transmission problems if not rectified, will cause expensive repairs or even replacement of the transmission assembly. Symptoms of a Transmission issue.
Engine light on dashboard. Vehicle struggling to accelerate, or engine speed increasing with no increase of vehicle speed. Shuddering coming through vehicle when driving.
Whirring, grinding or clunking noise coming from vehicle. Vehicle has no drive, or cannot select gears Common Transmission Issues Check Engine Light coming on On vehicles equipped with an automatic transmission, if the transmission computer detects an issue with the transmission, it will cause the to appear on the dashboard. This may be accompanied by vibration or strange noises coming from the vehicle.
It is recommended not to drive the vehicle in this condition and have it inspected as soon as possible, as it may stop at any time without warning. Strange noises while driving Transmission noises can be hard to pinpoint but they can usually be identified as a whining, clunking or high pitched humming noise when driving, depending on road speed. Driving with these symptoms is not advised and may cause further damage if the vehicle is not inspected as soon as possible.
Hesitation If your vehicle hesitates to take off from a stop, or the engine speed increases but the vehicle speed stays constant or slows down, this may indicate an issue with the transmission, or clutch on manual transmission vehicles. Car won’t select gears or go into gear If you cannot select a gear, or the car is in gear but does not drive, this indicates that there may be a simple issue such as low transmission fluid, or something more sinister – such as a failed clutch or valve body. Leaking fluid If you notice your vehicle, it is recommended to have it inspected as soon as possible to prevent damage to major components and to make sure it is safe to drive. Transmission Inspection Our mechanics will inspect under the vehicle for any leaks or damage to the transmission, check the level and condition of the transmission fluid and clutch fluid (if applicable) and road test the vehicle to ensure correct operation.
The mechanic will then prepare a quote for repairs or replacement if required. Transmission Repairs or Replacement Depending on what the vehicle requires, a repair or replacement of components will be carried out. The mechanic will then top up the transmission fluid, clutch fluid (if required) and carry out a full system test to make sure the vehicle is in full operational condition. A road test will then be carried out to ensure the repair/ replacement has rectified the issue and a final visual inspection to make sure no fluid is leaking from the vehicle.
Why is it Important to Have Your Transmission Inspected or Repaired? Having your transmission inspected as soon as an issue is detected is not only vital for the safety of you and your family, as well as other motorists – but may also save you money in the long run, by preventing further damage to the sensitive internal components of the transmission. These can be expensive to repair, and may require a complete overhaul if the issue is not diagnosed early. If you notice any of these symptoms, have your vehicle inspected by one of 1,600+ qualified workshops, or have a fully certified mobile mechanic come to your house or office – Too Easy! Image credit: Transmission.