VW T4 Transporter - HELP!

Clutch went so I bought a new unit, according to the manual, it should be possible to pull off the gearbox without dropping the engine out. It isn't. The manual is wrong. Brooklyn Books ltd. is the only publisher with a T4 manual and it is inaccurate rubbish.

That leaves me with a fairly precarious situation. Gearbox disconnected (finally) from the engine. Engine slung in a jury rigged hoist (picture is too embarrassing). Gearbox propped up on my only jack and the van barely high enough to crawl under.

That's where I got to before it became obvious that the gearbox will not fit past the front subframe. There's no room to pull it off. How to fuck do I get the subframe off and out of the way? Failing that, what tool do I need to disconnect the exhaust. Looks like a huge spring clip so assume it needs an equally huge tool, like a circlip expander.

I guess I ought to post a few pictures, if only for the general amusement of all. I have a horrible suspicion this van is now a write off

Screwd.

Tried asking here?
VWT4 Forum

Engine is supported on ropes but not easily lifted or dropped. The manual says it can stay where it is but is wrong.



Gearbox is a unit type so that big round thing on the right (the diff) has to pull forwards towards the driveshaft. "Disconnect the driveshafts and tie them up out of the way". There is no "out of the way"!



Gearbox is off and I assume resting still on the input shaft while the weight is supported on the jack. I don't know how far it has to come out, quite a bit more I suspect.

HELP!

Screwd.

Originally Posted by Adam

Tried asking here?
VWT4 Forum

Not yet, though I am on that forum. Probably cut and paste this thread.

I'll take out the bit about Brooklyn Books. Apparently it's already quite well known they are rubbish!

Screwd.

Originally Posted by Adam

Tried asking here?
VWT4 Forum

DOH! Good call, there's a thread on it. I need to wind the engine forwards. Right through two scaff poles!

Bugger!

Anyone got an engine hoist?

Screwd.

Originally Posted by Screwdriver

DOH! Good call, there's a thread on it. I need to wind the engine forwards. Right through two scaff poles!

Bugger!

Anyone got an engine hoist?

Screwd.

Have you got a longer scaffold pole to replace the top span so the uprights can sit outside of the wings instead of right in the way?

Originally Posted by stoo

Have you got a longer scaffold pole to replace the top span so the uprights can sit outside of the wings instead of right in the way?

Yes. I think tomorrow will be a day spent re-jigging. As luck would have it in that design, I can move the engine laterally by moving the tripod leg. Had I known, I would have arranged things differently. Still not sure about the exhaust clamp thing, might be easier to leave it in place and disconnect the tailpiece (while supporting it of course).

I've taken so much more off already than I had hoped to get away with. Bit worried about putting it back. And I'm taking it to Scotchland and back this weekend. What a test that will be!

Screwd.

You do need a special tool for the exhaust but it can be made.

Basically a ling piece of 8-10 mm threaded bar, 2 home made hooks either side of 2 nuts, wind the nuts apart to spread the hooks.

The above should make sense if your looking at it.

hth

Tricky to make a spreader I can get into that space and still operate but may consider it.



We'll see what tomorrow brings. I'm suddenly realising how far away Scotland is. last time I did it in a twin turbo scooby. You wouldn't believe me if I said how quick that trip was. the van, or at least this van, will be somewhat more sedate (albeit a darned site less expensive on fuel).

S.

Originally Posted by Screwdriver

Tricky to make a spreader I can get into that space and still operate but may consider it.

We'll see what tomorrow brings. I'm suddenly realising how far away Scotland is. last time I did it in a twin turbo scooby. You wouldn't believe me if I said how quick that trip was. the van, or at least this van, will be somewhat more sedate (albeit a darned site less expensive on fuel).

S.

Which engine has yours got?

My 2.4 is geared far too low so is neither quick nor particularly frugal. Can get low 30s mpg if I keep it below 60, but that's bloody hard to stick to on a run of that distance. Only get about 450 miles out of a tank at 80ish.... and it used to be loads worse than that before I got the pump timing sorted properly.

I keep thinking about fitting the 1.9TDI out of my soon-to-be-scrapped Golf in there....

Originally Posted by Screwdriver

DOH! Good call, there's a thread on it. I need to wind the engine forwards. Right through two scaff poles!

Bugger!

Anyone got an engine hoist?

Screwd.

Where are you? I have a hoist but it's in Norfolk.

Originally Posted by stoo

Which engine has yours got?

My 2.4 is geared far too low so is neither quick nor particularly frugal. Can get low 30s mpg if I keep it below 60, but that's bloody hard to stick to on a run of that distance. Only get about 450 miles out of a tank at 80ish.... and it used to be loads worse than that before I got the pump timing sorted properly.

I keep thinking about fitting the 1.9TDI out of my soon-to-be-scrapped Golf in there....

1.9d very nice engine with 100,000 on it. I reckon I am getting a good 40-45mpg cruising at 80-90. It was a very nice van but I was only ever getting stupid quotes for a clutch replacement, almost as much as it cost to buy it. Now I can see why. It clonks over speed bumps too but I can't find anything loose, would that be an obvious fault? Lower ball joint?

I am beginning to doubt I can get this back together, motd and confidently drive it 1000 miles in one day (Saturday). Maybe I haven't really thought this through.

Screwd.

Originally Posted by Zanx

Where are you? I have a hoist but it's in Norfolk.

Cheers Zanx but I'm in W. London, with no van! I'll do something with the scaff I guess.


Screwd.

Any updates?

Originally Posted by Spliffyaid

Any updates?

Yes. Despair. I gave up on it for today and will just have to leave it. I'd have to remove the RH support which means I need to construct a completely new frame to support the engine while I remove it. Or I could just bolt everything back together first.

Had a look at the exhaust clip which is also a bugger to get at. If I bodge up a tool it needs to be a good one because access is limited. I note on the VW forum this is a notoriously difficult job and people do drop the whole front subframe, engine and all just to get the gearbox out. VW use an engine jig which cleverly holds the engine when you drop and tilt it.

I need to be thinking about the Scotland trip. it ain't gonna be in that van.

Screwd.