Mini Cooper, Mini One, BMW R50 5 speed Getrag Gearbox strip-down

Following many requests to show a Mini Getrag gearbox being stripped down, here's a light-hearted look at a 5 speed Getrag disassembly using tools available to the DIY mechanic.

[@pinkyn0se]

About to take my gs5 apart, using this for reference... Even bought a 12 ton press! Wish me luck!

[@Kanc1erz]

Hello David, is there a need to tear down the whole gearbox if all gears are working very nicely, but the gearbox is whining? No matter at what gear. It is not whining when I press the clutch or there is no acceleration or deceleration.

[@Nogoslowly]

You can just strip it back to any stage you want. The main issue is that, if things are going wrong, it is very difficult to clean out any debris without fully dismantling it. Whine in all gears is most likely to be the differential, check the diff bolts are not loose and bearing are in good condition.

[@mohageli358]

Hi David enjoyed the video’s immensely. Could you please tell me where to locate a bill housing for r50 12/2004 mine was damaged due to broken bolt from crown wheel. By the way how to remove the broken bolt. Best of thanks

[@Nogoslowly]

One Stop Gearbox Shop may be able to help with a new casing but possibly cheaper to look for another a scrap 'box for parts. Diff bolt failures are common and they should be checked and reassembled with a thread locking compound. To remove the bolt I suggest you work from the unbroken side and tap with a centerpunch to rotate it back through enough to grip it with a mole wrench or similar.

[@markcoventry743]

Hello David, thank you for posting the videos for the R50 Mini Getrag 5 speed box. Do you know the torque for the blind bearing plate in the gearbox itself ? it has 2 torx bolts holding it in place. Thank you for reading.

[@Nogoslowly]

Getrag/BMW are not forthcoming with torque data for bolts but I use the standard torque for the bolt size and grade 8.8 - which can be googled.

[@davidbartling3963]

Ever seen one with only 1st and reverse gear? 2,3,4,5 all neutrals shift linkage looks to be actuating how it should. About to tear it apart

[@Nogoslowly]

I've never seen more than one gear fail at a time. 1st, 2nd, and reverse all use the same hub. So if 2nd is not there I suspect it's a cable problem, or gear stick mechanism, that is not giving enough throw to engage the gears.

[@mattybrining1768]

I’ve got an r56 6 speed box, do you know anyway of getting the primary and secondary shaft out without a press?

[@Nogoslowly]

It really is very difficult to remove shafts without a press. If you a re lucky, and can get the circlips off the bearings, you may be able to push the complete bearing on the six speed through the housing. But you'd still need to pull off the bearings to dismantle it further.

[@nitschke30]

Would you happen to know where I could find a replacement 5th gear?

[@Nogoslowly]

The 5th gear does tend to burn up as it is squeezed by 3rd and 4th as they migrate down the shaft. That's why we remove 5th in the racing boxes. It can be repaired by pushing 3rd and 4th back in place and replacing the bearing if it has melted. It's not readly available as a new part so, if you need to find another one, you really have to look at the secondhand market. Message @Duratec.in.detail on facebook and I may be able to help you locate one.

[@lofi_btz]

hello David! help me please! I have a 2004 Mini Cooper r50 and my midland manual transmission its broke and I would to know if its posible do a swap for one getrag like these. I read some posts that recomendly do this,

[@Nogoslowly]

It can be done but needs new driveshafts, flywheel, clutch slave cylinder, and gear stick with cables. So a lot to change really, and best done from a Getrag donor car.

[@ianbowen1855]

Hi David, my r50 5spd has done the imput shaft bearing. doesn't look to difficult to replace?

[@Nogoslowly]

It depends on which bearing you mean - the first input shaft bearing (from the clutch) is easy, simply split the casing and push it out. But I suspect you mean the secondary shaft one that support the drive to the diff. That's the one that usually fails and would require a new shaft and bearing. That is a full overhaul and may not be any more cost effective over sourcing a replacement gearbox.

[@brodiehaward]

My mini 5 speed getrag wont go into first, presumably lost the synchro. It will only go into first if i push it in without using the clutch whilst rolling or rev it high and push hard on it. Just completely locked out of first really. Any idea if this is definitely a synchro issue and anything i could try? Thanks

[@Nogoslowly]

If it is just 1st that's the problem, then it's probably a broken synchro ring. If other gears are a little difficult, then it's likely to be something dragging - ie 5th gear bearing being crushed, or 2nd gear bearing can cause a similar problem.

[@brodiehaward]

@@Nogoslowly yeah its just first gear. Im managing to live with if for now, as double clutching usually works to get it into first, however sometimes it doesn’t so i often depress the clutch and engage first before coming to a hault so i can always easily pull away again

[@law1298]

Hi Dave, I am up against a rock un hardplace my mini r50 2004 convertible had what thought was a thrust bearing gone after removed and replaced with complete clutch kit refitted to the car one other thing the used oil from the box was silver in colour and had swarf in it this was very fine like glitter gearbox totally drained fresh oil put in after refit still have a horrible wine grinding noise engine running select all gears all good in neutral no unusual noise depress clutch revs up no noise I then with front wheels raised off the ground release the clutch to drive the wheels spinning and the wine and grinding noise is there put a long screwdriver on the housing casing the noice is loudest when the screwdriver is placed on the diff housing I am changing up un down all gears no crunching forward gears and reverse gear no crunch , after about 10mins turned off " so have now removed the fresh oil and found glitter like in that too . I have removed the gearbox from the car I have phoned around near where I live and seems nobody wants to repair them only sell you a recon for very strong money my question to you is is it worth my while me spitting the box as I am thinking the problem I have is the carrier bearings in the differential please let me have your thoughts , kind regards Law

[@Nogoslowly]

From what you have described, it sound like bearings are failing. It may be the diff bearings, but all the bearings can fail so it's difficult to be sure without opening it up. You can buy an overhaul kit with all the bearings and seals for around £160. The risk is that the secondary shaft bearing surface has failed too - that would really make it beyond economic repair. There's nothing to loose by undoing the 17 case bolts and having a look.

[@law1298]

@@Nogoslowly Dave " Thank you so much for coming back to me I have looked in to doing that have seen the kits to rebuild I am retired now this is a car a purchased over the lockdown and after doing a lot of work on it and putting a new mot last month taxed insured then on the day of it's maiden run out this raised it's ugly head sods law" the thing is I do not have access myself to a press and the other specialist tools needed although I have asked a friend that do have a press at his works only thing that scares me is if it is bad and I can't fix it !! the recon places stipulate that they will place a hefty surcharge if the exchange box has been opened so will have to have a think ". ps sorry to babble on Law

[@law1298]

oh by the way that video is spot on"

[@Nogoslowly]

TBH, if it is beyond fixing, you'd be better to buy a complete 'box rather than exchange. They come up on ebay from time to time. And don't rule out buying a failed MOT car as that is often the cheapest way to get them, swap the boxes and then just sell the car on as spares, or for repair, or scrap it.

[@Litesnip2022]

Does the Getrag box have any common issues on the mini?

[@Nogoslowly]

The five speed box can have issues with the gears moving along the primary shaft and squeezing 5th gear (that's why it's replace with a spacer for racing). 2nd gear can wear synchro badly and is expensive to replace.

[@MrAlanbatson]

Love the video! But the music drove me mad :(