manual transmission/transaxle: service and...

2006 Mini Cooper S (R53) L4-1.6L SC (W11)

Manual Transmission/Transaxle: Service and Repair

Removing And Installing Transmission (COOPER S) Special Tools Required: ^ 00 0 200^ 00 0 201^ 00 0 202^ 00 0 205^ 00 0 207^ 00 0 209^ 11 8 260^ 11 8 401^ 11 8 402^ 23 4 010^ 51 2 160

Note: Check gearbox oil level.

Caution!: Use only approved gearbox oil.

Turn off ignition.

Disconnect battery.

Remove intake filter housing.

Remove bolts securing manifold heat shield (1).

Remove heat shield.Manifold heat shield ...................................................................................................................................................................................................... 8 Nm

Remove upper stabilizer bolts (1).

Remove stabilizer (2).

Unclip fuel pipe (3) and vent (4) from bracket.Upper stabilizer bracket to body mounting ............................................................................................................................................................... 100 NmUpper stabilizer bracket to engine mounting ........................................................................................................................................................... 100 Nm

Drain gearbox oil.


Remove left front wheel arch liner.

Remove both driveshafts with knuckle carriers.

Remove lower stabilizer fixings (1).

Remove stabilizer (2). Lower stabilizer to oil sump holder .......................................................................................................................................................................... 100 NmLower stabilizer to front axle .................................................................................................................................................................................... 100 Nm

Remove crush tubes.

Slacken modular front end and fit special tools 11 8 401 and 11 8 402

Remove front subframe.

Remove coolant pressure cap from expansion tank.

Remove oxygen sensor bracket bolt (1) and coolant pipe bolt (2).

Remove coolant pipe clip (3).


Fit engine lift bracket, special tool 11 8 260

Remove gearshift cables (1) from ball joints with special tool 23 4 010

Release gearshift cables from abutment bracket (2) and remove cables.

Remove clutch slave cylinder retaining bolts (1) and remove clutch slave cylinder (2) from gearbox.Slave cylinder to bracket

M8 ..................................................................................................................................................................................................................... 24 Nm

Remove reverse lamp connector (1).


Fit bonnet strut extensions, special tool 51 2 160

Fit engine support bridge to vehicle.

Use special tool 00 0 200 , 00 0 201 , 00 0 202 00 0 205 , 00 0 207 and 00 0 209

Tighten support bridge sufficiently to support engine and gearbox weight.

Remove throttle housing.

Remove supercharger inlet retaining bolt (1) and release hose clip (2).

Remove supercharger inlet pipe (3) to access pipes (4).

Note: Remove pipes via quick fit connectors.

Unclip slave cylinder pipe from gearbox and move to one side.Supercharger inlet pipe retaining bolt

M6 ....................................................................................................................................................................................................................... 9 Nm


Remove MAP sensor.

Remove MAP sensor pressure pipe from bracket.

Remove support bracket fixing bolts (1) and remove bracket (2)

Remove closing plate retaining bolts (1) and remove closing plate (2). Closure plate retaining bolts

M6 ....................................................................................................................................................................................................................... 9 Nm

Remove starter motor heat shield bolt (1).

Remove oxygen sensor harness from clip (2) and remove heat shield. Knock sensor to cylinder block ................................................................................................................................................................................. 22 Nm


Remove starter motor connectors (1) and (2).Alternator connection on starter ................................................................................................................................................................................ 14 NmEngine harness to starter solenoid ............................................................................................................................................................................... 8 Nm

Move harness from gearbox area.

Note: Starter motor harness routing.

Remove gearbox mount retaining bolt (1) and upper bracket retaining bolts (2) to gearbox.

Remove gearbox mount. Gearbox mount retaining bolt to upper bracket .......................................................................................................................................................... 66 NmMount bracket to gearbox ........................................................................................................................................................................................... 66 Nm

Lower engine approximately 135 mm.

Remove gearbox retaining bolts.

Remove gearbox.Gearbox to engine retaining bolts

M12 ................................................................................................................................................................................................................... 85 Nm

Note: Assistance is required when removing and installing gearbox.

manual transmission/transaxle: service and...

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