T4 Strange Noise

[melissa]

My 2003 T4 Manual Kombi gets serviced and generally well loved by me. It just does the normal mum stuff of running around and has only been as far North to Valla (last year) and just been to Canberra at easter which is as far South as it's ever been. It is just a couple of k's off 61,000klms...so it's out of the 3 year warranty but by no means driven into the ground.

I've had "little" issues with the dealer here (which I didnt buy it from) and its only been there for its first service and warranty work- it always needed to go back after a new problem would arise from a visit to the dealer Its been serviced by a mechanic that has always looked after our VW's and I trust him.

Anyway enough of background.. last week I noticed when my hubby reversed out of the carport (its usually me driving NOT him) and I was outside the Kombi that there was a noise coming from the passenger side front wheel that sounded a bit like a rotating grating noise..the front wheel was at a hard turn, it's in reverse, maybe with foot slightly on brake as it goes downhill on a small slope and you can hear it from inside the car now as well. So I took it up to the mechanic to book it in for today and asked him to listen as I started to back out. He stopped me quickly and asked "It's still under warranty isn't it?" I said Nope...he didn't look too good...

So it went in today for the service and he has written a note and thinks it could be the Reverse Idler in gear box..front brakes will need to be done in 5-10,000klms...so it looks like its off to the dealer..the dealer that doesn't like me...
so how many banks do I need to rob? anyone else had this happen? Do I have ANY recourse through VW if the gearbox is cactus? 61,000klms!!! .....

oh...and I think I have found a spot of rust near the windscreen...and I don't live near the beach..and it lives in a carport ...
did I get a Friday afternoon special??????

[syncro]

If you have had your car serviced by VW, they may help you out.
Give them a call.

I think that you may still have a warranty as far as rust goes. (5 years?)

[melissa]

It was only the first service by VW...but all of the other services have been written up...I think my mechanic is VW approved or something like that...but servicing doesn't include the gearbox anyway..does it?

I thought paint etc was 5 years too, so that might be Ok.

[brackie]

Gearbox noise?

I can't make the connection between a scraping from the front wheel and a stuffed reverse idler! Get a second and third opinion before you fork out any cash, Melissa. Gearbox overhauls are very costly and at 60k shouldn't be necessary. It's obvious that you look after your vehicle and I'd be very surprised if the gearbox is at fault.

[Golf Loon]

My T4 gearbox has just done 200,000 with no probs.
I cant believe yours is stuffed.
Could it be the undertray rubbing on the wheel? Or a CV?
Get someone uninvolved to look at it.

[Seano]

I'm with Brackie on this one.

If the brakes need to be done then get them done. Then see if you still have the noise....

....the number of times I've had to dig rocks and other crap from between the caliper, disc and sheild of the front brakes is......interesting.

You could also be hearing the front CV joint under load (slow speed, hard turn) - which may not be a problem - just normal. Still worth looking for breaks in the protective boot (unlikely but worth a squiz).

[melissa]

Thanks for the replies guys.

I know the brakes were cleared when he checked the pads but I will get VW to have a look/listen.
I knew I should have taken up the offer of extended warranty but when I read into it - it didnt cover this and it didnt cover that- so I didnt bother, just kept up the Volkswagen Assist membership.

[jets]

I agree with the other members comments re the noise--- good advice.
Re the rust around windscreen, have you ever had the windscreen replaced?
There is often damage done to the paintwork when they dig out the old trim & screen. My van has a very small spot of surface rust where 2 panels are joined near the pillar. I have thought it not worth paying to get it fixed & have stopped it progressing by a small spray of Lanotec, a lanolene based spray that protects metal from rust but can be removed easily if painting in the future.

[melissa]

No, the windscreen has never been replaced (no chips either). The spot I am thinking is starting to rust is a join. It's very small at the moment (looks a bit like a split, about the size of a grain of rice) but I want to get it checked out before its too late. I'll try to take a photo tomorrow..just tried but its too dark

[melissa]

Now With Pictures!

The close up probably makes it look worse ....


This should give you an idea of where I am talking about..


Another shot...

[syncro]

That rust looks like warranty to me.

[jets]

The rust in my van is in exactly the same position[LHS ONLY] but yours looks more advanced than mine. If VW won't repair it then I would either repair it yourself or get it done. I understand the rubber trim is easily removed & at this stage probably with the right procedure an easy permanent repair. Don't whatever you do let it go. In the end it would be a windscreen out job & lots more money.

[melissa]

Can I ask how old your van is Jets?

Thanks Phill..they will be seeing me in person on Monday (I have work and a funeral so can't get there until then)

[WEDEL.1]

Those small indents are to help water escape from under the rubber/plastic trim. Late models had 3, one each end & one in the middle.

Dietrich the Green T4 only has the two (one each end), and so far has no rust. Two years ago we had to have the windscreen replaced, and I looked at the recess where the windscreen sat with great interest, luckily there was no rust.

I'm sorry to hear of your problem. It always saddens me when someone has problems with a T4, because they are such a great car.

Hope all works out well.

Maris

[melissa]

Thanks for the reply Maris. My Kombi has 3 of those little "V" shapes across the front but this rust spot is on the right of the "V" in the photo below..



As you can see, its small for now...and when my hubby finds out he is NOT going to be happy...I've kept it secret from him so far... he has never really liked my Kombi...could have something to do with trading in the 85.. he has never gotten over it...it's always been "Too red" or "no soul". Every time I have had to take it back to get this fixed or that fixed he has said "should never have gotten rid of the 85 "