Question about 2004 Mini Cooper

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CVT 2002 Mini Cooper transmission check and change

I have a 2002 Mini Cooper with a CVT transmission. None of the Dealer material tells you how to check or change the trans fluid and when to do same. Any Idea what happening?

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  • easpfx Apr 09, 2009

    Like so many others, the 5-speed gearbox in my 2002 Mini Cooper had expired. Completely! Any Mini dealer wanted 7k (+-) to put in a new one. Any reputable garage wanted 4.5K (+-) to install a re-build. So I decided to take a crack at it.

    I tore out my 2002 Mini 5-Speed Gear Box (GS5-65BH). I dissected it down to the bone, replaced the alignment shaft-ball bearing, the output shaft roller bearing, L & R Axle seals, and the alignment-shaft, guide-tube & seal.

    In my case, the transmission alignment shaft ball-bearing had completely come apart. I fished all eight of the hardened steel balls during disassembly, and not a one was touched. This was further evidenced by the lack of any hardened chips or splinters on the fill and drain plug magnets. The only metal on the magnets was from the metal casing of the alignment shaft cover.

    I re-used all of the spring clips and hardware, that the manual recommends tossing for new.



    Cost Approximately $240. , parts and shipping. And 24 man hours. Now I have to fill it with fluid and I'm told I have to use theirs, which is $24.00 pr. L tr., ( 2 required).



    I have crossed the BMW edict against re-building the trans. I took a step inside, and I can tell you, "it's just a 5-speed gearbox folks". In fact its quite a simple and elegant design. I don't know why they are always breaking!



    Can't I just run a good synthetic, like Mobile-1? If so, what weight range.

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The only way to check the trans fluid is to drain the fluid right out of the trans pan. There should be 5 liters. The only way to get the fluid in is by pumping the fluid back in by means of the fill plug on the lower front of the transmission. I believe it is a 4 or a 6mm allen to remove the plug. Whatever you use to pump the fluid back in needs to seal where the fill plug is because fluid will pour right back out. I would change the fluid at least every 50k.

Posted on Mar 17, 2009

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