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 Posted October 1st, 2010 at 12:22PM
So despite either off-courses or coned runs on every try, I was having a blast at the new Fortitech site during the September 19 autocross. Until my fifth run when I broke another axle.
I had replaced both driver’s side and passenger’s side axles on the car in the previous week, to “level 0″ axles from the Drive Shaft Shop. This after the clamp on my “level 2″ loosened and began spitting grease again, and the other side exhibiting perhaps interesting clicks and clunks. So I changed them both, and the driver’s side broke again.
I ran around like a chicken on Monday, inquiring as to the status of my Level 2 (which had been sent back for re-clamping and a check over) and ordering a stock replacement from Keeler in case the Level 2 did not come back to me in time. The Drive Shaft Shop agreed to repair the level 0 given that I had it on the car less than a week, and sent the refurbed level 2 back to me in no time at all.
When I tried to put the OEM replacement axle in, I could not for the life of me get it to snap in. The circlip, grind, and everything else looked identical. It just wouldn’t go in. So I threw the level 2 back in, clicking easily into place.
The car ran without fault at Monticello that Friday, September 24. I had a blast, but two other MINIs were not able to run that day. One went into limp mode on the drive down, while the other discovered a torn CV boot. I offered to give him my spare (I had an extra for both sides that day), but he left early.
I was signed off to solo and enjoy possibly the last two hours I’ll ever have on the Monticello Motor Club full course configuration. I enjoyed myself. This was the first track event hosted by MoHud SCCA in a long time, and by all accounts it was pretty successful.
Oh, I also bought a 2004 WRX. But that’s another story altogether. Come on, snow!
Posted October 26th, 2009 at 11:21PM
The track day at Lime Rock was a success. The predicted precip never materialized and the sun even peaked out a few times. Still chilly. Plenty of no-shows. The MINI ran without fault. I made progress by the end of the day after spending the morning perpetually screwing up big bend and the left hander (turns 1 & 2). I was content after 80 minutes of track time but left itching to go back. I can see myself having a lot of fun at LRP.
The Kumho XS tires worked out. Despite temps in the 40*s, they were able to generate some heat and feel grippy.
Finally, I think I’ve basically gotten this axle issue resolved. I removed it again because it was spitting grease. After a call to the Driveshaft Shop, they sent me a package with some replacement clamps, boot, and bag of grease. Popping the boot off to pack more grease in was a mess initially but I figured a way of getting it back together and sealed again.
With the bracket filed down, there’s still just a slight indication of scraping on a nearby bolt. Both bolt and bracket are mounted to the subframe, and I’ve since come to the realization that engine movement is to blame. Changing motor mounts (especially the upper hydraulic one, which failed awhile ago, leaking its fluid all over the frame underneath) may solve the axle issue as well as some of the wheel ‘hop’ during launches.
But as soon as the white stuff starts flying, it’s time for one last wash and wax, and then the MINI gets stored for the salt season!
Posted October 11th, 2009 at 12:22PM
So the warranty replacement for my first $130 axle broke at MoHud’s last event of the season, October 4th. (Outer CV broke at the turn before the finish lights on my second run after a spin during my first: I finished 4th in class with a decent time for a second run that morning. Go figure. The MINI likes that ACC lot, but the lot does not like cars – there were other casualties, including two half-shafts on one scoob.)
I AAA’d it back home once again. I was promised a refund for the cheap axle (still waiting), and after a call to The Driveshaft Shop, I learned that they do indeed have plans for R53 MINI axles. They’re still $100 less than OEM and feature beefier CV joints, supposedly rated for 450hp. I ordered one on Monday and got it installed Wednesday.
Seems fine, but there’s a slight vibration I’ve never noticed before under heavy acceleration in 1st and 2nd. It’s not really a CV joint noise though, and I can’t recreate any clicks or clunks under any driving to indicate another bum axle. The car is sitting at 63k miles, and they’ve been hard miles, so it’s time to start watching wear items like wheel bearings and bushings carefully. I’m confident this vibration doesn’t indicate an imminent failure though. I’m just pretty paranoid about any new NVH at this point.
To make sure, I decided to check out an autocross Saturday put on by the car guys at RPI. The night before I was able to get my Kumho XS mounted at their community supported auto shop, so this was a chance to break in the tires too.
Saturday was a fun, friendly atmosphere, but I didn’t get much driving in. After two runs, the car began making a clicking noise. Jacking up the car, I found (stick with me here) the inner CV joint boot’s clamp on the new axle had been catching on a bracket for a wheel sensor mounted on the a-arm. The beefier joints on the new axle have less clearance with this bracket, which I noticed while installing. Under normal driving, it wasn’t an issue. With lateral loads on the car, however, the bracket moved upward enough to snag the clamp. Halfway through my cautious drive home, the clamp was pushed off, but the boot stayed on so no loss. Today I’m going to see about filing that bracket down a bit. I’m going to head to a shop on Monday to see about putting a new clamp on the boot, as I can’t get the old tweaked clamp anywhere near tight enough with ordinary pliers.
I’m definitely glad to have caught this small issue in Troy yesterday as opposed to Lime Rock Park next Saturday. I can’t help but feel anxious whether or not the car will have any issues there, even though everything has been checked and all preparations made in recent weeks.
Most disheartening is the weather forecast for next Saturday. There’s a huge cold front coming from Canada, making its way through practically the whole country, hitting our area this weekend. Day highs in Lakeville, CT are supposed to reach the mid 40s, with a 50% chance of morning precip in the form of rain or, yup, snow. I’m not sure I’ll mind taking it extra gingerly as it’ll be my first visit to the track. Nicer weather would have been appreciated though. 
Posted August 17th, 2009 at 12:53PM
Yesterday was another local autocross, this time behind the Boscov’s at Clifton Park Center. This was the first time we ran at this lot (last season, we had a smaller lot in a different location at CPC) and I was fairly impressed. From what I felt, there were none of the crashing bumps that reveal themselves at speed at our Adirondack Community College or McCarty Ave. parking lots. Small, but then I drive a small car, so I can’t complain about that too much.
Unfortunately, the MINI failed in spectacular fashion. First run of the day: I come into a single-cone turnaround pretty quick, brake, smooth downshift to first, coming out of it, time to apply some throttle…. Nope, somebody replaced the go-pedal with a “bag of rocks” pedal. The driver’s side axle I replaced in May broke, the outer joint shearing out of the socket, spraying ball joints across the parking lot.
I’m not entirely sure I got to apply any throttle at all. It was a vicious 180* turnaround, and the axle might have given loose as a result of the downshift adding a bunch of revs in the middle of the tight turn.
It had been clicking for a bit, becoming more noticeable after the last autocross and throughout my trip to Calabogie last month. My bad, shoulda been more proactive. I’m honoring the lifetime warranty, at least until I find or can afford something more robust.
Fortunately I was able to use AAA to get the car home, and it looks like I’ll only be out S&H on the replacement axle. Oh, and I might as well buy that large 30-something MM socket, as it looks like I’ll be doing this job more than once…
So without a single run, I finished DFL and DNF in Street Mod. Behind three Volvos!
Posted June 3rd, 2009 at 12:04PM
So the MINI sat with its broken axle for about two weeks before I had the opportunity to fix. After researching my options, it became clear that they were… limited.
I could get a remanufactured axle for $75, plus a core charge. Or, fcpgroton.com offers a brand spanking new DSS axle for $139. The OE replacement from Keeler would come in at $516. I checked raxles.com but they unfortunately did not have a MINI application.
I went with the DSS axle, as my research turned up mixed results with them — as opposed to universally bad results with remanufactured axles. Also factoring into my decision was the lifetime warranty with the DSS, and the lack of a core charge, meaning I could keep my stock, broken axle for possible repair at a later date. Ordering from fcpgroton.com was a breeze. Once I had the axle in my hands, it was clear that the rubber boot material was flimsier on the DSS axle than on the OE, however it was the correct size and fit + finish seemed A-OK.
The install was not very difficult, even though I prepared for the worst. I could not figure out the trick to undoing the tie rod or control arm attachment points without the special tools, but by popping out the strut, I was able to rotate the hub far enough away to make installing the replacement axle possible. Install time was 2-3 hours, which is about normal for most people, and absolutely great for someone with my inadequate mechanical skills. I did not have difficulty removing the stock part, and the DSS slid in and locked into place easily.
I’m still on edge about any new roughness or vibration, but as of yet, with perhaps 500 miles and last Sunday’s autocross, it has held up fine and exhibits no worrying symptoms at all. The next big events for my MINI and I are the June 13-14th National Tour at Seneca Army Depot (autocross), followed by two days of track time at Watkins Glen with Patroon BMWCCA.
A post with results from last Sunday’s autocross is forthcoming.
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