Tried asking here?
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
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.
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!
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.
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).
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....
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.
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.