Clutch Masters 07-14 Mini Cooper JCW 1.6L Turbo Aluminum Flywheel
The Clutch Masters FW-635-AL is a lightweight billet aluminum flywheel for the second-generation Mini Cooper S and John Cooper Works with the 1.6L turbo and manual gearbox, listed here for 2007 to 2014. It is meant for the owner who is replacing a tired dual-mass flywheel, already has a Clutch Masters clutch on the shopping list, and wants the quickest-revving setup available for autocross, track days or a hard-driven street car. It is a conversion part and only works with a Clutch Masters single-disc kit.
The factory flywheel on these cars is a dual-mass design: a primary and secondary mass joined by springs that filter engine pulses before they reach the gearbox. It is quiet when new, but the springs and center bearing wear, and extra boost speeds that up. The FW-635-AL replaces it with a single solid flywheel. Clutch Masters CNC machines it from 6061 aluminum billet, zero balances it, Type 3 hard anodizes it for wear resistance and certifies it to SFI 1.2 for motorsport use. Its boxed shipping weight is about 11 lb, much lighter than the stock assembly, so the engine picks up and drops revs faster between shifts. Clutch Masters also sells replaceable steel friction inserts for its aluminum flywheels, so the clutch face can be renewed later without replacing the whole part.
Be honest with yourself about use. Clutch Masters says lighter flywheels make more gear noise and usually recommends steel for street cars, saving aluminum for builds chasing the least rotating weight. If the Mini is your daily, the FW-635-SF steel flywheel for the same cars is the calmer choice.
A noise that changes when you press the pedal is the flywheel or release bearing talking. A tach that rises ahead of road speed under boost is a slipping disc, which a new clutch fixes whether or not you change the flywheel. Our slipping diagnosis guide covers the road test, and the flare versus slip guide helps you separate a clutch problem from other drivetrain noise. Check for oil at the bellhousing too, since a leaking seal will ruin the new parts.
Our listing names the Mini Cooper JCW 1.6L turbo, 2007 to 2014. Clutch Masters lists FW-635-AL for the 1.6L turbo manual Cooper S from 2007, the Clubman 2008 to 2014, the Countryman from 2011 and the Paceman 2013 to 2016. Engine and drivetrain details changed during that run, and all-wheel-drive Countryman and Paceman models may differ, so send us your year and VIN and we will confirm before it ships. It does not fit the 2002 to 2006 supercharged Cooper S, the non-turbo Cooper, the later 2.0L and 1.5L turbo cars, or any automatic. Pair it only with a Clutch Masters FX100 to FX500 kit, such as the FX100 kit sold without a flywheel; it will not work with the factory clutch or another brand's kit. More parts are in our rebuild kits category.
Clean the crankshaft flange, inspect the rear main seal while it is exposed, and fit the flywheel with new bolts torqued in a cross pattern to the values in the supplied instructions. Clean the friction face, center the disc with an alignment tool and tighten the pressure plate evenly. Bleed the clutch hydraulics with the fluid marked on the reservoir cap and refill the gearbox with the Mini-specified manual transmission fluid. Follow the Clutch Masters break-in of at least 500 miles of normal driving with no full-throttle shifts before you push it.
| Brand | Clutch Masters |
| Part number | FW-635-AL |
| Fits | Clutch Masters 07-14 Mini Cooper JCW 1.6L Turbo Aluminum Flywheel |
| Vehicle fitment | Mini Cooper Jcw (2007-2014) |
| Type | Flywheels |
| Condition | New |
| Ships | Same business day (in stock), from the USA |
| Warranty | 1-year |
No. It is a conversion flywheel that works only with a Clutch Masters FX100 to FX500 single-disc kit. It will not work with the OE clutch or another aftermarket brand.
Clutch Masters lists the 1.6L turbo manual Cooper S from 2007, Clubman 2008 to 2014, Countryman from 2011 and Paceman 2013 to 2016. Our listing names the 2007 to 2014 JCW. Send your VIN and we will confirm your car.
It can be, but expect more gear rattle at idle and a touchier launch. Clutch Masters usually recommends steel for street cars, and the FW-635-SF steel flywheel covers the same Minis.
Yes. Clutch Masters offers replaceable steel inserts for its aluminum flywheels, so a worn face can be refreshed without buying a new flywheel.
You need a Clutch Masters single-disc clutch kit and new flywheel bolts. Inspect the rear main seal and clutch hydraulics while the gearbox is out.
Drive at least 500 miles normally with no full-throttle shifting or hard launches so the disc beds in evenly against the new flywheel.
