2004 Volkswagen T5 2.5 Gearbox, clutch and DMF removal and replacement Part 1
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- čas přidán 22. 05. 2021
- Clutch has been slipping for a few months so decided to investigate what was going on. It was not good news....
Some of the parts and tools used in my videos:
36v 350W Speed controller with battery level display and speed level control :
ebay.us/t8WOS2
Ignition Switch:
ebay.us/18oWxI
The actual Go Kart used in the build:
ebay.us/7GGuFA
Remote activated relay (For killing the power in the event your child tried to make a run for it):
ebay.us/drH4ep
18650 battery charger/tester (Opus BT-C3100):
ebay.us/FMnvbT
Oscilloscope Multimeter:
ebay.us/qGwZA3
Spot welder:
ebay.us/tnaTbk
Nickel plated strip:
amzn.to/3yr1FD3
Music supplied by Epidemic Sound:
www.epidemicsound.com/referra... - Zábava
I've been working through my t5 ,camshaft ,turbo ,alternator etc and doing dmf is the next on the list and I was worried about having to do it on my driveway but seeing that it can be done is a relief .....great video ,so helpful and much appreciated and subscribed
Thanks very much for the comment Peter. Its people like you that makes spending 10 hours under a van with a camcorder worthwhile! It absolutely can be done, just take your time with it and maybe get a second pair of hands for lifting the gearbox in and out.
Thank you for this video! Just spent the weekend swapping out the clutch and DMF in my '06 2.5 T5 and this was such a great reference. That gearbox is not an easy one to manoeuvre.
Thanks for the feedback. Makes the whole video worth doing when I know it's been a help to others like yourself.
I'm planning a gearbox swap on my FL 2.0 TDI from 5 speed to 6 speed. This video alone helped a lot on how it should be done.
Comments like yours makes making these videos all worth while. Thanks for sharing.
i cant thankyou enough for this i need to do my clutch on my 2007 t5 with the same engine so this is a god send
Adie your comment has made what was frankly a ball ache of a video all worth while!
Thanks so much and I really hope your clutch change goes well for you too. Should save you a ton of cash doing it yourself.
Fantastic vid. Just going to have a go at changing my clutch on my 2015 6 speed t5.1 and looks similar to this gearbox. Hopefully this will help as I've never done anything like this before. Wish I had your garage with all that head height and light
Thanks for the comment. Best of luck with your van. It maybe a little daunting at first but as you get into its really not that bad. Take your time and if its outside book yourself some good weather!
Nice work - and a tonne of confidence and know how. I am having this done at a specialists mechanics to my 2012 T5 automatic diesel: "Labour, CARRIED OUT DIAG, Carried out
removal of gear box due to Disengagement and vibration , found fly wheel and failing and double clutch damaged". Just to do that will take 16 hours. (That is, more labour will be required to repair or replace and install damaged parts.).
Wow! That is some work you got there to do. As much as its going to hurt your wallet in the short term, in the long term there is no better feeling than when your behind the wheel driving down the road knowing your not going to have to worry about doing that job again. Thanks for your comment and good luck with your repair!
Thanks for the reply. I did not word my above question properly - apologies. Does 16 hours for that job described inside the speech marks, sound right? To me it sounds excessive, but I am not a mechanic. How long did your job take please without the benefit of a work mate or a garage shop's equipment - and while holding a camera?@@SlightlyModifiedUk
@@tt-kn6wn apologies for not getting what you meant there. It took me a good day to get the old gearbox out and the clutch and flywheel off. That's a good 8 to 10 hours. I did go at it pretty hard but also did stop along the way when my son decided to help etc. It took about the same to put it all back together, maybe a little bit longer as getting that big gearbox back in place on my own was a little tricky. With the aid of a ramp and gearbox stand I think I would have certainly shaved off a good couple of hours off the disassemblely and about the same resembling. Not sure what difference an automatic transmission would make to the time or if yours was a 4 motion for instance. Hope this helps anyhow.
It does help, mate - thanks.
I do not know about mechanics, so my money is in the hands of someone else when it comes to trusting them on what they say about costs, labour, need for parts, etc. (I could not even word my first question properly, so God help me if I take a spanner to a motor!). From what you have said, there 16 hours seems excessive, but there is little I can do. Thanks for your post - I envy your talent.
.@@SlightlyModifiedUk
Really pleased I could help you. Would love to know the outcome when you know it yourself. Best of luck with yours!
Great video thanks
Respect 💪🔧
Thanks for the video. I've decided I'm not up to the task. I've got bearing noise and I'm ordering a complète set of bearings cos 1500€ for a recon gearbox is way too much.
Lovely 😍 👌
Very helpful
Many thanks.
Nice to see question is why not repair? Worn bearing would have been my first thought reconditioned is always risky thats why i always trust my own gearbox. Would like to have. K own what failed. Do you have 5 or 6 speed. I have the 1.9 5 speed t5 beat version to buy according to forums so i got one light on feul are you able to get a solid clutch not the dual mass?
Your right, it's a fair question and the simple answer is that I did set out to have the gearbox repaired and even took the box to my local gearbox specialist. They stripped the box down to repair it but told me that the whole box was worn and not just the input shaft and bearings. They showed me where the gears on another part of the box had been rubbing the inside of the casing. It was well and truely worn out. Like you I would have preferred to get my box back but the cost was double that of an 'off the shelf' reconditioned one. To confirm your right about not trusting a reconditioned box, the first replacement box I got was no good so had to go thorough the whole process swapping it for a 3rd time some 3 weeks after making this video. Not ideal! Anyhow the one in the van now has about 5k on it and made a 1,500 mile round trip to Germany without any issue.
My box was the 6 speed which does seem to cause more problems than the 5 speed by all accounts. The clutch I used was the original spec dual mass version. Not cheap but oem and does give me nice feeling of satisfaction knowing its all new now and not going to need replacing for a while.
Impressive job. Was considering doing the same on mine, but not sure I'm brave enough after seeing this. Did you manage to film the rebuild?
Brilliant video thankyou very much, i need to change the whole alt drive inside the timing cover, leaking oil badly and the rod looks bent or maybe the shimms it sits in are elongated, this is a great help, how was it getting the box back in please ? and how many miles on the box ? Thankyou . Peace.👍
Thanks for comment. The gearbox was a little difficult to get back in on my own but by preparing things before hand it went pretty well. I would recommend a rachet strap around one end of the box and a trolley jack under the other half that way you have complete control over not only the hight of the box but also the tilt. Getting it on the spline of the clutch is always the difficult part and this is a big old gearbox! The old gearbox had about 160,000 miles before it needed replacing. Hope this helps and best of luck doing yours!
@@SlightlyModifiedUk Thanks for the reply, this will help so much, I really appreciate it and for taking the time to make the video, thankyou 👍. Peace.
How long this removal operation stand?
It took about 5 hours to remove and replace the clutch and flywheel. It then took about the same amount of time to put it all back together again.
wouldnt it be easier to remove engine and gearbox and split on floor to change clutch?
In some respects your right it probably would be. However at the time I never considered it, I'd also probably have needed an engine hoist which I don't have.
Super Mann....
Danke
how much was the reconditioned box please?
The gearbox on it's own cost me about £1,200 ($1,460) inc delivery and taxes.
@@SlightlyModifiedUk did you rebuild the old gearbox and sell it? I would. They're making sil money hère in Paris.
Silly money. Damned autospell!
@@kevinhayden1 Sadly not as the replacement gearbox was an exchange unit so had to send the old one back. However I did look at rebuilding it before hand but the bearings had let go pretty much and had already started hitting the gearbox casing. Wouldn't have been a great box no matter what I did with it sadly.
Merhaba transporter T5 2.5 kullanıcısıyım aracım yolda giderken stop etti bir daha çalışmadı ustalar arızasını bulamıyor
I'm very sorry to hear this. I hope you got it sorted