I thought I had read about others having the same problem, but I can't find the answer...

I have owned my 03 MCS since new. In the course of 6 years and 43,000 miles I have had it to the dealer no less than 5 times for a recurring noise from the clutch (sounds like "VROOT") when starting from a stop in first gear. It happens intermittantly and only in first, usually when starting up over a speed bump or driveway incline. It still operates normally but the sound is obviously not "normal" and sometimes when in neutral with the clutch out, it makes a vibrating sound.

In the past the dealer has conferred with HQ and has replaced the clutch several times, the throw out bearing and even the flywheel, all to no avail as the sound comes back in 5-7000 miles. It isn't due to abuse or driving style (I have driven manual trans cars for 40 years and never had to replace a clutch). One time the mechanic at the dealer said the factory had experimented with some sort of split pressure plate and it wasn't a good engineering attaempt so it is problematic.

The last time I had it in the dealer's service manager gave me a "Extention of warranty" on the clutch for 2 more years. It is now 22months later and the sound has returned. The dealer now says they can't hear the noise so no repair. I know what is coming form all the other times it has made the sound and been replaced.

Has anyone experienced a similar problem? If so were there any repairs done?

I love my Mini but I can't see spending $2500 for a new clutch every 7,000 miles.