Transmission VW Transporter T4 - dismantling
Volkswagen Transporter T4 car on a lift (installing it on a “pit” or overpass), you can remove the gearbox down.
A vehicle jack is required to support the transmission during removal. Regardless of how the car was raised, it is necessary to install powerful stands under the body frame. ♦ Remove the terminals from the battery.
♦ Remove the engine cover and tilt the front of the car forward.
♦ Place a jack under the VW T4 gearbox or hang the engine on a winch and lift it until the cables are taut.
♦ Disconnect all electrical wires from the gearbox, disconnect all its
control rods.
Disconnect the speedometer cable bracket from the transmission. ♦ Disconnect the linkage lever from the gearbox before removing the clutch slave cylinder.
If the vehicle is equipped with a five-cylinder diesel engine, use fig. 332:
Rice. 332 Disconnecting gearshift levers
♦ Unscrew the fork head connection (1) from the front of the gear selector lever, remove the selector lever (2) from the pivot.
♦ Unscrew the bracket with lever assembly (3).
♦ On manual transmission vehicles, disconnect the clutch cable from the
clutch switch lever as described above.
♦ Disconnect the speedometer drive from the gearbox.
♦ Disconnect the coolant pipe from the starter from the expansion tank to the water pump (see arrow fig. 333).
♦ Disconnect the electrical wiring from the pipeline.
Rice. 333 Bolts of fastening of a tube of system of cooling
♦ Remove the upper bolts securing the engine to the gearbox T4.
On petrol engines: Disconnect the vacuum brake booster hose from the engine.
Diesel engine 1.9: Disconnect the drive cables from the engine.
♦ Mount the tool VW 3250 (see Fig. 334) so that the left axle shaft, shock absorber screw and connecting rod (stabilizer on the right) can be removed. The stop (A) of the tool must be in front of the upper steering knuckle. The V-notch (B) rests against the attachment bracket (2).
Rice. 334 Installing tool VW3250
Attention: install the VW 3250 device before lifting the body, in the initial state of the suspension.
♦ Remove the shock absorber fixing screw and connecting rod (stabilizer) from the right.
♦ Disconnect the ground bar from the gearbox and crankcase bracket.
Remove the starter.
Diesel engines: Disconnect the brake booster hose from the vacuum pump.
Diesel engine 2.4: remove the generator.
♦ Disconnect the gearbox support (A) from the clutch housing (B) and from the engine. On fig. 335 shows a 2.0 engine gearbox support.
Rice. 335 Detaching power unit support bracket
Engine 2.0: remove the screw securing the engine to the gearbox located above the clutch housing.
Remove the shield located on the bottom of the crankcase. ♦ Loosen the mounting bolts and disconnect the left and right drive shafts from the gearbox.
In this case, it is necessary to use multi-sided wrenches, since TORX type bolts (with multi-sided sockets) are used for fastening. Turn the wheels to the right until they stop. Reject the axle shafts so that they do not interfere during the removal of the gearbox, hang them on a wire or a strong cord to the body so that the CV joints do not bend more than 15-20º. Models with air conditioning: remove the air conditioning compressor from the engine and hang it on a wire to the body. ♦ Release models up to 08.92: dismantle the rear gearbox support Transporter T4 together with the console (see arrow in Fig. 336). If necessary, move the power unit slightly forward.
Rice. 336 Dismantling the rear support of the power unit
♦ Models from 08.92: Detach the powertrain rear mount. Remove bolt (C), tilt gearbox forward and remove gearbox support (see Fig. 335). Disconnect the speedometer drive cable from the right drive shaft housing.
Rice. 337 Fitting VW tool 3230
♦ Mount the auxiliary rail VW 3184/1, for the VW 3184 tool, on the front beam (see arrow in fig. 338). If necessary, disconnect interfering piping and wiring.
Rice. 338 Installing tool VW 3184/1
♦ Fasten special tool VW 3184 to the bracket VW 3184/1 and to the rear attachment brackets (A), inserting the lever of the tool VW 3230 into the slider (B) (see fig. 339).
Rice. 339 Installing tool VW3184
♦ After installation, tighten the locking bolt (C).
♦ To remove the release bearing bracket from the Volkswagen T4 gearbox, lower the unit.
♦ Detach the stabilizer on both sides and push it up until it stops to make room for the exhaust pipe.
♦ Disconnect the front exhaust pipe from the resonator or catalytic converter.
4-cyl. engine: remove the exhaust pipe/auxiliary tank guard. ♦ Place a VW 1383 jack under the gearbox and remove the remaining screws securing the gearbox to the engine.
♦ Check that all connections between gearbox and engine are disconnected.
Given the large number of model variations, this book is beyond the scope of a detailed description of all possible connections. Work is best done together. ♦ Use a pry bar to move the gearbox away from the engine, making sure that the gearbox does not fall off the jack and “hang” on the input shaft.
♦ Jack up the T4 gearbox so that the wires do not snag on the gearbox brackets. Have an assistant support the gearbox on the jack until it is removed from under the vehicle.