MINI 2002-05

Transmission Removal & Installation

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Cooper Coupe



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Battery and battery box
     
    Manifold heat shield
     
    Engine stabilizer (upper)
     
    Fuel and vent pipes from bracket near stabilizer
     
    Drain transaxle
     
    Front left wheel well liner
     
    Driveshafts with steering knuckle carrier
     
    Lower stabilizer
     
    Front subframe
     
    Gearshift cables from ball joint attachment
     
    Gearshift cable bracket
     
    Clutch slave cylinder from transaxle
     
    Reverse lamp connector from transaxle
     
    Brake booster pipe from manifold (push down circular ring to release)
     
    Coolant pressure cap from fill tower
     
    Oxygen sensor bracket, coolant hose clamp, and bolt
     

  4.  
  5. Install a engine lifting eye bracket, 11-8-260 as shown.
  6.  
  7. Support the engine with lifting equipment.
  8.  
  9. Raise equipment enough to take weight of engine and transaxle
  10.  
  11. Remove the upper bracket retaining bolt (1), mount to transaxle bolts (2) and remove the transaxle mount.
  12.  
  13. Lower the engine about 1.5 inches (40mm).
  14.  


    Click image to see an enlarged view

    Fig. Installing engine lifting eye bracket-Cooper Coupe



CAUTION
DO NOT lower engine too much or exhaust system could be damaged. Also watch A/C pipe to compressor when lowering engine.

  1. Remove or disconnect the following:

    Starter heat shield
     
    Oxygen sensor wiring from clip
     
    Starter
     
    Closure plate bracket around inner driveshaft opening
     

  2.  
  3. Support transaxle with suitable jack.
  4.  
  5. Remove the transaxle retaining bolts.
  6.  
  7. Remove the transaxle.
  8.  


NOTE
Shorter 2 bolts are located into oil pan.



Click image to see an enlarged view

Fig. Identifying the location of the transaxle mount-Cooper Coupe

To install:

  1. Clean all mating surfaces.
  2.  
  3. Position the transaxle into the vehicle.
  4.  
  5. Install and torque the transaxle-to-engine housing bolts to 63 ft. lbs. (85 Nm).
  6.  


NOTE
2 shorter bolts go directly into oil pan.

  1. Remove jack.
  2.  
  3. Install and torque closure plate bracket bolts to 7 ft. lbs. (9 Nm).
  4.  
  5. Install or connect the following:

    Starter; torque bolts to 63 ft. lbs. (85 Nm)
     
    Starter heat shield; torque bolts to 7 ft. lbs. (9 Nm)
     
    Starter electrical connections
     
    Oxygen sensor to clip near starter heat shield
     

  6.  
  7. Raise the engine back into normal position and install the transaxle mount. Torque the bolts as follows:

    Mount bracket-to transaxle: 28 ft. lbs. (38 Nm)
     
    Mount-to-upper bracket: 49 ft. lbs. (66 Nm)
     

  8.  
  9. Slowly release engine tension from lift equipment. Remove the equipment.
  10.  
  11. Remove the engine lifting eye bracket.
  12.  
  13. Install or connect the following:

    Coolant hose, clamp and bolt
     
    Oxygen sensor bracket (near coolant hose)
     
    Brake booster pipe to manifold
     
    Reverse light switch connector
     
    Clutch slave cylinder; torque bolts to 18 ft. lbs. (24 Nm)
     
    Gearshift cable and bracket
     
    Front subframe
     
    Lower stabilizer bracket (2); torque bolts (1) to 74 ft. lbs. (100 Nm)
     
    Driveshafts and steering knuckle carrier
     
    Left wheel well liner
     

  14.  
  15. Refill the transaxle with proper oil.
  16.  
  17. Install the upper stabilizer bolts. Torque the bolts to 74 ft. lbs. (100 Nm).
  18.  
  19. Attach the fuel and vent pipes to the upper stabilizer.
  20.  
  21. Install the manifold heat shield.
  22.  
  23. Install and connect the battery.
  24.  
  25. Start the engine and check transaxle operation.
  26.  


    Click image to see an enlarged view

    Fig. Showing the upper stabilizer bracket and bolt locations, plus the location of the fuel and vent pipes-Cooper Coupe


Cooper S Coupe



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Battery and battery box
     
    Intake filter housing
     
    Manifold heat shield
     
    Engine stabilizer (upper)
     
    Fuel and vent pipes from bracket near stabilizer
     
    Drain transaxle
     
    Front left wheel well liner
     
    Driveshafts with steering knuckle carrier
     
    Lower stabilizer
     
    Crush tubes
     
    Front subframe
     
    Coolant expansion tank cap
     
    Oxygen sensor bracket, coolant hose clamp, and bolt
     

  4.  
  5. Install an engine lifting eye bracket, 11-8-260 as shown.
  6.  
  7. Remove the gearshift cables from ball joint attachment, with special tool 23-4-010, then remove the gearshift cable mounting bracket.
  8.  
  9. Remove the clutch slave cylinder from the transaxle.
  10.  
  11. Disconnect the reverse light switch connector from the transaxle.
  12.  
  13. Open the hood to the full upright position and install strut extensions, 51-2-160, to hold the hood in this position.
  14.  
  15. Support the engine with lifting equipment.
  16.  
  17. Raise equipment enough to take weight of engine and transaxle.
  18.  
  19. Remove or disconnect the following:

    Throttle housing
     
    Supercharger intake hose
     
    Detach other pipes by quick-fit couplings
     
    Slave cylinder hose from transaxle and move aside
     
    Closure plate around inner driveshaft opening
     
    Starter heat shield
     
    Oxygen sensor from clip on heat shield
     
    Starter connections and move wiring harness aside
     
    Starter
     
    Transaxle mount
     

  20.  
  21. Lower the engine about 5 inches (135 mm).
  22.  
  23. Support transaxle with suitable jack.
  24.  
  25. Remove the transaxle retaining bolts.
  26.  
  27. Remove the transaxle.
  28.  


    Click image to see an enlarged view

    Fig. Installing engine lifting eye bracket-Cooper S Coupe



    Click image to see an enlarged view

    Fig. Disconnect the gearshift cables from the ball joints-Cooper S Coupe


To install:

  1. Clean all mating surfaces.
  2.  
  3. Position the transaxle into the vehicle.
  4.  
  5. Install and torque the transaxle-to-engine housing bolts to 63 ft. lbs. (85 Nm).
  6.  
  7. Remove jack.
  8.  
  9. Raise the engine to normal position.
  10.  
  11. Install or connect the following:

    Transaxle mount; torque bolts to 49 ft. lbs. (66 Nm)
     
    Starter; torque bolts to 63 ft. lbs. (85 Nm)
     
    Starter electrical connections and wiring harness
     
    Oxygen sensor to clip near starter heat shield
     
    Starter heat shield; torque bolts to 7 ft. lbs. (9 Nm)
     
    Closure plate bolts to 7 ft. lbs. (9 Nm).
     

  12.  
  13. Install the lower support bracket and torque the bolts as follows:

    Mount bracket-to transaxle: 28 ft. lbs. (38 Nm)
     
    Mount-to-upper bracket: 49 ft. lbs. (66 Nm)
     

  14.  
  15. Install or connect the following:

    MAP sensor
     
    Slave cylinder hose to transaxle
     
    Supercharger, pipes and hoses
     
    Reverse light switch connector
     
    Slave cylinder to transaxle; torque bolts to 18 ft. lbs. (24 Nm)
     
    Gearshift cables and bracket
     

  16.  
  17. Slowly release engine tension from lift equipment. Remove the equipment.
  18.  
  19. Remove the engine lifting eye bracket.
  20.  
  21. Install or connect the following:

    Coolant hose, clamp and bolt
     
    Oxygen sensor bracket (near coolant hose)
     

  22.  
  23. Install the front subframe; torque bolts to 74 ft. lbs. (100 Nm)
  24.  
  25. Reinstall the MFE to its normal position. Torque the bolts as follows:

    M8x30 bolts: 17 ft. lbs. (22 Nm)
     
    M6x16 bolts: 3 ft. lbs. (5 Nm)
     

  26.  
  27. Install or connect the following:

    Crush member-to-subframe: 74 ft. lbs. (100 Nm)
     
    Lower stabilizer bracket (2); torque bolts (1) to 74 ft. lbs. (100 Nm)
     
    Driveshafts and steering knuckle carrier
     
    Left wheel well liner
     

  28.  
  29. Refill the transaxle with proper oil.
  30.  
  31. Install the upper stabilizer bolts. Torque the bolts to 74 ft. lbs. (100 Nm).
  32.  
  33. Attach the fuel and vent pipes to the upper stabilizer.
  34.  
  35. Install the manifold heat shield.
  36.  
  37. Install and connect the battery.
  38.  
  39. Start the engine and check transaxle operation.
  40.  

 
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