T4 Syncro clutch needs changing - who?

[Racemag]

I need a new clutch in the T4. It's a syncro 2.5 petrol dual cab. I want the rear crank seal and gearbox seal done at the same time - where can you get this done for a reasonable sum?

[Racemag]

Oh, in Melbourne

[MadMentalist]

To cut a long story short, Paul Adams motors in Geelong replaced my syncro clutch after it failed an hour into the great ocean road! Last minute and a good price although he may well turn you down after the amount of times I heard him say the C word when I picked the van up from him!

[Racemag]

I've been told the Syncro is difficult.

[jets]

I can't see it being much more difficult compared to a 2WD. Paul Adams would probably have difficulty with a standard van as well. Most of the problems seem to be related to not having done one before. I spoke to a guy in Adelaide that changed his many years ago[petrol syncro] because his usual mechanic put his van in the air & decided he didn't want to do a clutch replacement. The owner said it took him some time but had success & he's not a mechanic. I didn't ask the question on whether he removed the engine & gearbox together or just the gearbox. From what I have read removing engine & gearbox together might be the better option.
Please repost on how you get on.

[MadMentalist]

The difficulty is the transfer case for the syncro system will not clear the subframe without a good amount of brute force and ignorance. Paul Adams told me that it was very tight but he was able to do it without removing the engine/box. If I remember correctly he told me he had to drop a couple of the engine mounts to twist it enough to get the box undone a free from the bell housing...

[Racemag]

I contacted Boris at Volkscare and he offered a good price and seemed undaunted by the job. I pick it up tomorrow.

[Racemag]

Clutch change all good. New clutch, oil, gearbox and crank seals plus linkages with new bushes (I supplied) for slightly less than $1300. Took it on himself to fix a starting problem and did well. Seems like a good man and a good business. Will follow up with a service.

[Sunny43.5]

I changed the clutch in my work van few years back myself , had a mate sort of helping it took us around 8 hours would have been easier if we had a hoist so working on ramps and using jacks to lower the box out was a real treat NOT ! Yes had to partially lower the subframe so to speak to get clearance for removal .

[MadMentalist]

Sounds like you got a win there!

[Sunny43.5]

Yes I was sort of happy to get it done but as mentioned twisting and manhandling it around to get out was a bitch , especially when you are laying on your back with the whole box resting on your chest !! Worse part for me was to discover some months later the mongrel had a DMF inside which I was unaware of and its still there shuddering its heart out whenever I have to reverse up an incline . Oh the joys of VW .

[Racemag]

Fortunately no DMF - they were on the later Ateco tranny synco's and not my 02G one. Have done 300km now. Car starts better than ever before and runs well. Notchy gear change is taking a while to get used to.

[Sunny43.5]

Lucky you then I was under the impression that as VW were the designers of the DMF they shoved it every model they had . Apparently it was made for diesels to lower the throb of the engine so I am blowed why the hell they fitted it to petrol model ones .

[Racemag]

I was warned, but I'd had a look and was sure it was solid. I will add that Boris had the T4 for 4 days in order to fit it in around other jobs. Still starting well. Could do with another 20kW

[jets]

Fortunately no DMF - they were on the later Ateco tranny synco's and not my 02G one.

what's an Ateco trans? Does he mean VW? Are you sure you have the 02G gearbox? My understanding is the 02G is only used on the TDI diesels & the V6 petrol.