T5 1.9 tdi gearbox

[BBVWT5]

Hi All,

I have a 2009 T5 1.9tdi 5 speed manual BRS engine code, wondering if anyone out there has had chattering noises in 1st and 2nd gears with the 5 speed manual box, I think I am needing a rebuild so have a few questions. Also need to replace clutch and possibly DMF as it has had a judder for some time now. Any info on the the following you can provide would be greatly appreciated:

1. Gearbox removal - how to's, to drop subframe, what happens to power steering lines, remove drive shafts completely etc?
2. Gearbox codes - where to find codes on box or chassis plate. VW tell me the codes (from my VIN) are JQT and 02Z type, can anyone confirm this?
3. Thinking I need to do clutch and flywheel as well, if it turns out to be a Luk unit can I replace the flywheel and clutch with a Sachs kit if I also change the DMF to suit?
4. Rebuild kits from eBay, looks like the bearing kit is the cheapest option and guessing this is the problem as still have drive and no bangs (yet) or complete failure.
5. Output drive shaft on drivers side will also be replaced at same time.

Anything else I have missed in my research?? !!! Anyone with experience on this would be great to hear from,

huge thanks, Ben

[Sunny43.5]

Yes lots of swearing filthy hands and make sure you have a few friends around the gearbox weighs a ton ! . On a serious note yes you will need to lower the subframe front end to allow space to get the bugger out . From memory I only loosened the power steering bits and left them in situ . Drive shafts removed fairly easy job , only near mistake was crushing the power steering line on refitting but it was okay . I did not do the DMF as I did not know VW had put that mongrel thing in a petrol powered van when the DMF was developed for the diesels to absorb the engine throb . So here I am with the same DMF with over 250K on the clock yes it's shagged but as long as I don't reverse into a steep hill it's fine . I used original VW parts for the job , from memory the shaft drivers side was around the $460 mark and the clutch kit with throw-out bearing around the $650 mark . Took myself and a friend around 8 hours with no hoist !! just a few blocks and some jacks and a pair of ramps . The chattering is probably the drive shaft as that what mine used to do , this what it looked like when remove the splines were only a fraction of their normal size due to wear .http://www.vwwatercooled.com.au/foru...n-img_7474-jpg

[BBVWT5]

Awesome thanks for your help. I'll be doing it on the ground as well... thinking the chatter is either the drive shaft stub axle as you mentioned or a main shaft or layshaft bearing, will get it apart and probably take to a gearbox place where they can press in a new set of bearing for me (only about $350 from ebay from UK with all seals etc as well). Clutch and DMF looks to be around $700 from UK including postage which isn't too bad considering VW wanted over 2k !!! btw VW quoted around $8000 in parts alone to the job, not that I would ever trust them to do a proper job anyway but thought I would ask as a reference point I love VW's but I'm going back to Toyota after this saga!!!