T4 drive train mystery - 2.5l 5 speed manual

[T4 hobart VW]

Greetings - its my first post so go easy on me please ... I'm new to water-cooled VW's.

I've recently purchased a T4 2.5l petrol 5 speed van - it has issues but most I'm able to sort.
It does however have an issue with the drive train - The engine runs fine but no powers getting through to the wheels.
I've done some homework and think I have it nutted down to two possible issues.
1) - if the clutch has stripped or broken in the centre spline then the power wouldn't get through to the wheels.
2) - if one of the CV's or an intermediate shaft in the diff is stripped then neither wheels would turn

Is there any short cuts to nutting out this issue ?
Is the T4 5 speed prone to powertrain issues ?

With the engine running and wheels up and no clutch depressed I can change gears with a positive feel to the stick - the wheels rotate but without any force and you can stop them with your hands. It feels like the centrifugal energy is dragging the drive train along. Wheels down I can't drive absolutely no power to the wheels !
Clutch seems to be working - well at least the pedal goes down with a positive feel no idea if its working the thrust release bearing but no weird noise from the bell housing however !
Checked gear linkages all look like they could do with a freshen up but seem to work fine !
Previous owner said the stick came out in his hands a couple of times but wasn't related to the current issue.

My moneys on the clutch but I don't know if they are prone to shearing the central spline ?!


I have stripped out the driver side CV and heading next to the passenger side trying to eliminate a broken/stripped CV - and then its on to removing the clutch.

Transmission is a CPV
Engine is a 81kw ACU
build date 09/95

any suggestions greatly appreciated.

also love any suggestions for T4 resources on line - I'm chasing a few parts.

Trying to think VW - its much harder than bee keeping !

[LogicprObe]

I never busted a drive shaft in my T4 but done a couple in my T5.
Had the driver's side CV collapse ...............and you certainly know it when that happens.
Also, the clutch tends to make a racket and be very difficult to change gears on the way out.........but it still goes!
Ripping the centre out of one.......well........you'd have to be doing burnouts or something, I'd reckon!

[Sunny43.5]

If it has the same sort of drive train as the T5 my money is on a stripped spline on the drive shaft .If you look here you can see the shafts with the worn spline and yes they will just let go without much warning . I was lucky as I could feel a strange slackness and backlash on acceleration and coasting . Scroll down to photos.2005 2.0 petrol manual T5 drive train spline question . I got my T5 ones from this place in Brisbane they were great to deal with .About Us – Australian CV

[T4 hobart VW]

Thanks for the intel the pic's show what I think is an intermediate or stub shaft that the T5 has and is prone to failure. - Ive done the preliminary removal stuff , mechanic friend suggested that a stuck on slave could also cause the problem so I removed the slave and while it was loaded a bit it didn't seem to engage the clutch.
Now down to the gearbox and diff removal - have devised a plan to hopefully lower the box out once its detached, I hear its a tad heavy.
Doesn't look like its going to clear the sub frame if the gearbox spline is long but the manual says it should just pull off ! Well everything else has come of with no hassle so I'm hoping its true.

So I'm now down to 2 possible causes - sheared clutch friction plate centre spline or a diff/gearbox issue !
My money is on the clutch cos its an easy fix and I know what I'm doing ...

well another day of grease but with more swearing I suspect !!!

[jets]

There is a couple of ways to remove the gearbox, the way you are doing, but some say it's easier to remove the engine & gearbox together after removing the front. The benefit of this method is that you can deal with any leaks at the rear of the motor. It is sometimes recommended to replace oil seals above oil filter either side of oil cooler.

[jets]

Is the T4 5 speed prone to powertrain issues ?
also love any suggestions for T4 resources on line - I'm chasing a few parts.

I am not aware of any issues.

What type of parts are you after?
I would try & buy any heavy parts like a clutch kit locally. I always get a quote from VW first as a datum.
Importing can be expensive for freight, even more so if you need to return the part.
I use a company called Imparts but they are trade only so you will need to use a friend's account. I don't know if there is a branch in Tas.
For small parts I have used VW Heritage a few times in the past & found them knowledgeable & easy to work with.

[Sunny43.5]

Like Jets said easier to remove the whole drive train , I did a complete engine transplant on my sons T4 2.4 diesel converted to 2.5 petrol during the process I was able to pull the motor out in a very short time on my own with a hired engine lift . The whole front of the van comes off with afew bolts naturally the coolant and hoses need to be disconnected and wiring .

[T4 hobart VW]

I looked at removing gearbox and engine together but as it has aircon I think I would need to gas down the aircon as the compressor would need to come out with the donk - my manual doesn't cover this ... let me know if I'm wrong please !!!

Had a VW mare last night - dreamed the differential was cactus ....

Will wait till the box is out but wondering if its worth a rebuild !

[Sunny43.5]

If its like a T5 the gearbox can be removed in situ but you need to loosen off the cross member under the car , its a heavy lump so you need a few helping hands to get the box out from underneath and the van needs to be high enough off the ground to allow for removal once on the ground . Yes you would need to degass the aircon as there is a coolant thing infront of the radiator .

[LogicprObe]

Pretty sure there'd be plenty of second hand boxes around at a reasonable price...............but if you have it out......you might as well put a new clutch in! (or at least a new thruster...........I might have made 400K except for that!)