Mini Cooper 5-speed Transmission

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 or ‘Midlands 5-speed’ Gearbox.

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 R65 gearbox 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, repair 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.

Mini Cooper 5 speed transmission

New Brake Cooling System under Test

Performance Mini Cooper Brake Cooling System upgrade for your front brakes reduces peak operating temperatures for improved braking performance. Greatly reduces brake fade with stock brakes and lowers peak temperatures on big brake kits. This kit is recommended for track use.

The PBCS diverts high velocity air from under the lower control arms and directs the flow to the rotor. This track proven set-up greatly reduces peak operating temperatures for consistent and predictable braking performance throughout an event.

The PBCS for the MINI uses a design commonly found on Porsche and BMW track cars. Unlike other kits that require ‘cutting’ of the bumper and inner panels, this is a complete ‘bolt-on’ kit that requires NO modifications to your MINI. This is a track set-up due to reduced clearance under the inlet scoop. If the car is driven to the track on the street, we recommend you remove the inlet scoop to prevent possible damage from road debris – you simply remove a hose clamp and zip ties to remove the scoop.

This kit consists of a pair of custom high quality TIG welded black anodized backing plate, a pair of highly durable Polyethylene Intake scoops designed specifically for the MINI, 500°F Silicone ducting, and all hardware for a complete installation.

This product is currently only available for the first generation of the BMW MINI Cooper (2001 thru 2006 models) but the great news is that testing is now under way to provide a kit for our later models!  Keep an eye on the New Products page of Mini Mania.

Sprint Booster- ‘A must have!”

After reading about the Sprint Booster on earlier postings, I was able to track down some info at SprintBoosterSales.com

After an email exchange with Ken at: info@sprintboostersales.com, I decided to take the leap and order one of these units. Without dragging this out, let me just say that it is SUPERB and worth the cost (IMHO)! I finally figured out how to install the thing (it was easy, but, of course, I tried the hard things first) and it works as advertised.

Gets rid of all throttle lag – much MUCH faster throttle response – makes the car feel like it has at 10-15% more power (though, of course, that is really unchanged) due to the quickened throttle-engine response. I believe that this is much the same feeling that one would get with a “chip” flash. It chirps tires in 1st and 2nd without trying to do so and the backend squirms as the power is “put down” faster… Impressive for a plug-and-drive device.

All of the usual “doubters” out there will be questioning this, I am sure, but until you’ve tried it – save your comments and doubts for yourselves!!! I got the same reaction to my news on the InaZma Max Voltage device and those of you who have tried it know what a great unit that is!!! This is even better!

Mini Cooper Transmission Problems

Seems as though we have had a recent rush on questions and problems related to the various transmissions that have been used in the MINI Cooper since it’s introduction in 2001.  Most people had heard about the update of the internal gears in the popular 6 speed manual transmission as used in the MCS.  And we finally hearing from some people actually trying to take advantage of the improved ratio by simply swapping a late tranny for the early one. From all reports the mechanical swap is not a difficult one and the results reported from more than one person can be quoted as ’stunning’!  But there is a drawback!  In return for all that greatly improved old fashion acceleration you will have to give up a modern sought after feature: cruise control.  While not specific to the transmission upgrade, the ECU for the MCS for ‘05/’06 models and the only feature lost in this trans swap is the cruise control.  Those that we spoke to said it was the only issue and was a small price to pay for the improved performance.
On  a negative front , we have also now heard from several people that are having problems with their automatic transmission as found in the very early MC & MCS.  These CVT were innovative when introduced and engineered to use the best torque and HP from the MINI engine to provide smooth and effortless movement.  But reliability was is biggest issue and while the tranny was replaced a few years later with a more convention automatic with their heavy torque converter, etc, the upgrade was proof that even the factory was convinced that the CVT could be used for the long term.  The real bad news that as the factory forecasts come true with CVT failures (most of them “out of warranty”- the current owner is faced with the reality that the ONLY solution is a new CVT transmission that is only available from a dealer for $5,000+ OUCH!  I would thus advise anyone considering a MINI Cooper automatic to stay away from the CVT version!

MINI Cooper S Convertible Spare Tire question

Question:

I have an ‘05 MCS convertible. I am sick and tired of the run flats. they have useless tire life and are hard and noisy. I have gone through 6 in 19000 miles.

My question is will the spare ft in the trunk with the top down or up? Where do you put the spare if it does not fit? If it will. I am inclined to replace the run flats with normal tires and get the spare.
Response:

Yes, not many people stay with the runflats for the reasons you mentioned.

The spare fits upright in the boot area although it does take up a fair bit of space. The only alternative is a flat repair kit like our Mobility Kit or the roadside assistance from your car insurance carrier. In either case, you may need the tools to change the tire, not all MCS came with them. You should have these tools.

Cooper S Body Kits

Question:

Just wondering if you has any comments on the fit of your aftermarket body kits (CarZone KIT). Do you also sell Hamann kit for this body style. I am picking up my JCW Cooper S today and would like to get a nice body kit for it which does not look aftermarket asnd fits like factory, your comments are appreciated.

Response:

Almost all body kits including Carzone and Hamann, will require some ‘finishing work’ to get the pieces to fit just right.  Some body kits will require some fabrication for the mounting.  We don’t know of any body kits where you can simply paint and install.

The Orciari body kit is one of the better quality body kits we have seen.  This kit is made from ABS plastic instead of fiberglass (like the Carzone and Hamann).  ABS plastic tends to have better fit and finish.

Since you have a convertible, your MINI has the rear proximity sensors.  Most body kits do not accommodate for this feature and will require additional work to adapt this to the body kit.

If you want a factory looking body kit on your convertible, I would recommend the factory Aero Kit from your MINI dealership – they have options for the rear proximity sensor.

What is the oil capacity on a 2007 Mini Cooper

Question:

What is the oil capacity on a 2007 Mini Cooper, non-S, with filter change? Is 5W30 preferred over 5W50? Why?

Answer:

For your 2007 MINI Cooper non-S, I would recommend you use whatever viscosity is specified on the decal on the valve cover of your engine. MINI specifies API SH specification or higher on the synthetic motor oil with a volume of 4.2 liters or 4.4 US quarts when replacing the oil filter. On our Cooper S, the label states 5W/30. MINI approved oils belong to the 5W-40 and
5W-30 classes.

They also caution not to overfill.

I strongly recommend you stay with the recommended viscosity due to various components in the 2007 engine affected by hydraulic pressure. This includes the VANOS variable valve technology, on-demand water pump, and on-demand oil pump.

Mini Cooper Window wiper failure

Queston:
hi just wondering can u help me what it is that my mini cooper front window wipers have just stop working.but the back ones are stil working and i have no idea wot it can be. Please can you help.

Response:
It’s difficult to tell without inspecting the car, but I might suspect a problem with the washer relays (there are two in the fuse box in the engine compartment, one for speed, one for on/off).

If not the relays, perhaps the wiper motor…

The only fuse for this system is common with the General Module, so that probably isn’t it since your rears work.

Mini Cooper Air Filter

The amount of horsepower an engine makes is directly related to the mass air flow of the engine. Mass air flow is determined by volumetric efficiency VE, and the density (pressure-and-temperature) of the air. In turn, if you know the actual efficiency of the engine, and energy content of the fuel used, you can predict horsepower. Assume a 97.5% VE at 5400. At standard temperature and air pressure (77 degrees Fahrenheit, and 14.53 psi) this equals 22.56 lbs/hour air. Assuming 19000 BTUs per gallon of gas and a 0.33 (mechanical x thermal) efficiency this should produce 228 hp. Converting the mass flow to CFM = 309CFM. Now, add a K&N cone air filter into the picture. It may positively impact VE due to a lower air pressure drop at 309 CFM than the stock filter. Let’s say VE goes to 98%. Mini Cooper Cold Air Intake System

Based on the same calculation, the mass airflow is now 22.68 lbs/hr or230 HP. However, consider the temperature of the air. Under the hood, without any type of insulation, the temperature is probably not far from the temp of the thermostat. To be conservative, let’s say the new cone filter is breathing in 160 degree under hood air instead of 77 degree air. Using the previous formula, but adjusting the air temperature what is the mass flow rate? 19.64 lbs/hour. That amounts to 199 horsepower. Here are calcs for a couple other temps at 98% VE:

Temp	Mass Air Flow	Predicted HP
40	24.36	247
77	22.68	230
100	21.75	220
120	21.0	213
140	20.3	206
160	19.64	199
180	19.03	193

 

Which means that for every 60 degree C the density changes by 10%. Assuming the engines volumetric efficiency stays the same, then we get 10% more power out of an engine, if we can reduce the inlet air temperature by 60 degree C.