Failed oil cooler in my T5

[sga]

2.5L TDI 128kw T5 van, build date Nov 05, 6sp auto. Purchased new Feb 06 and to date have done just 61000km. Private non-commercial use only (camping and around town) and always serviced on time. So I was VERY disappointed to find oil in coolant at 59,000km. Took it to a VW dealership and they diagnosed a faulty oil cooler which needed to be replaced and said that VW recommend also replacing the water pump at the same time!
I was horrified to get a bill for $2150 and very concerned that either of these parts, especially the oil cooler, should fail after just under 60,000km - 160,000km would still be too early wouldn't it ?
What else might fail prematurely despite looking after my van and keeping up servicing it regularly through VW dealers, and what might it cost??
I have heard that some have had their T5 gearbox fail before 100,000km. VW told me if I had to replace my 6sp auto that it would cost me $9,200 !

Have there been any common/major faults with the T5 diesel auto vans?
With careful driving and proper care and servicing, I was hoping for at least 250,000km free of any major problems (engine,transmission, suspension).
Hope some of you can advise me please.

[BrianJ]

I can't find the thread now, but I believe there is a recall by VW to replace faulty oil coolers on pre 2006 models. I enquired and found that my May 2006 model was not included. I don't see why you should pay, the dealer should have looked this up and determine if yours was on the recall list.

Brian

[Transporter]

I also think that you shouldn't pay for replacing both (water pump and oil cooler). Let them diagnose it properly just like they would do if it was still under the warranty! Unless they do it for free. The reason behind is, when the vehicle is under warranty, VW make us run to the dealer more than once to fix one fault (pinpoint exactly what the problem is, what part failed), so by now they should know what the problem is... water pump or the oil cooler! They didn't want to waste their money on the car in first 3 years, so why repair it differently now! Contact VW Australia and demand repairs to be done under the statutory warranty (contact ACCC for details about statutory warranties).

[sga]

Thanks for the tip Brian, I'll check with VW Aust. on this.

[sga]

Thanks for your quick response Transporter, I'll look into this for sure. Do you know of any other T5 engine/trans/suspension components that i should be worried about failing prematurely?
Cheers

[Transporter]

Have a look in here and scroll the page down. http://www.vwwatercooled.org.au/f136...are-32995.html

Components to be worried about: Water pump, oil cooler, power steering pump, air con, auto transmission, DMF, turbocharger (variable vanes like to seize if you drive gently 100% of the time), valve train (camshaft, rockers) if you didn't use right oil /VW approved/, drive shafts,
That's just from the top of my head.

[sga]

Thanks again Transporter for your helpful advice.
Cheers

[Tornado T5]

My van is a June'07 build and had it's oil cooler replaced as part of a factory recall program.

I started this thread which refers to the problem:

http://www.vwwatercooled.org.au/f136/dealer-service-t5-engine-oil-cooler-replacement-campaign-18002.html

Mention the replacement campaign as VW didn't officially classify it as a recall
EDIT 1: Just looked at the sticker the dealer placed on the drivers side door pillar and it states: Recall code 35A7.

EDIT 2: I had my gearbox replaced for a flaring issue that couldn't be fixed by software upgrades so they changed it over. I believe the cost you mentioned is about right. Should add this happened at about 65,000 km from memory. And my warranty runs out on 10/7/10 so I'll book the 90K service first and purchase an extended warranty.

Good luck!

[sparkyvwT5]

Exhaust manifolds can crack, Mine went at 67,000 (2006 128kw) , and the turbo is part of the manifold so to replace the whole thing would be $$$'s. Luckily they can normally be welded, which in my case only cost me $400. I have heard about the gearbox woes as well, so ive decided to have the fluids and filter replaced in mine when it is serviced next week, might see if they can do a software upgrade on the auto box as well.

[sga]

Gday Tornado I rang VW Australia in Sydney with my VIN No and asked if it was included in the recall but alas it wasn't, even though they still seem to be replacing, the cooler, under recall, in 2006,7 and 8 models! One presumes they are still using faulty units - does this mean we should expect our replacement units will probably fail too in about 60k?? As for your gearbox having to be replaced after only 65k - blimey ! why are we still volkswagen fans ??

[Tornado T5]

Gday Tornado I rang VW Australia in Sydney with my VIN No and asked if it was included in the recall but alas it wasn't, even though they still seem to be replacing, the cooler, under recall, in 2006,7 and 8 models! One presumes they are still using faulty units - does this mean we should expect our replacement units will probably fail too in about 60k?? As for your gearbox having to be replaced after only 65k - blimey ! why are we still volkswagen fans ??

I'm really sorry to hear that. I don't know how you can find out however is the unit being replaced under the campaign different to your failed unit? I don't know what the difference is with the units the dealers are fitting.

With regards to the gearbox, keeping it short, it was faultless prior to an oil change that I requested even though it wasn't needed and based my decision on reports I read out of the UK. Sure enough it started flaring a few weeks later, coincidence..can't say but they felt it was the elcetronic control unit and a replacement was the instructions from VW Aust.

[Rebuild]

gearbox maint, if you feel inclined
how to change T5 Auto Gearbox Oil - The Brick-yard

and
Tiptronic autobox failure!! - The Brick-yard - Page 1

[Deeceer]

Perhaps the water pump was one of the new 'more reliable' types but they were concerned about it having had oil through it.