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Hi I have a very annoying problem with my 2004 2.5 TDI 130 bhp transporter. The van suffers from a shudder under load at approx 1500rpm, however if you change down a gear and increase revs this does not occur. It is most noticable on the motorway from approx 55 to 80 mph.
To try and rectify this I have carried out the following replacements.
New dual mass flywheel and clutch
2 new driveshafts
3 engine mounts excluding gearbox side.
full compression test to eliminate any engine problems causing a misfire under load.
5 injectors reconditioned

The wheels & tyres have been replaced with 20' and brand new tyres. (the shudder was apparent with the old wheels as well)
The engine was replaced 15000 miles ago as the van had covered 120000 and was breathing heavily, or so the previous owner was told. The only thing I suspect may be the gearbox as this has covered 136000 miles to my Knowledge.
The van has had new bottom arms drop links discs & pads shockers coil springs etc.
I am desperate for anyones help on this matter as I have run out of ideas.
Simon
 

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My T5 130 auto was doing the exact same thing and I was having to drive it manually to keep the revs up. Took it in to the garage and it was the No. 3 injector.

Garage replaced the injector and the injector loom and the van drives like it should. I used a genuine VW injector and loom.


What did VAG com software tell you before you started replacing all those bits, and who diagnosed whatever fault thay suggested all those bits needing changing? If it wasnt you then take it back to them.:eek:

I dont think the gearbox would cause your problems.

Plug it in to VAG com software and see what it tells you?
 

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Had a similar problem...... Although mine was idle upto 1500rpm, in mare in traffic. Spent a packet, Cost me Two Clutches/Flywheels as the shudder obliterated one and the other was on it way. Engine Mounts, Cam Shaft Sensor, Crank Sensor and Various other sensors.

Nothing ever came up on VAG Systems, Local Garage Systems (Snap-On Scanner, Laptop with VW System and a few others), Diesel Tech System, BOSCH Diesel Computer while I was in Germany and Even VW Tech Bod at MK HQ (I was up there for Bodyshop Training) couldnt find anything, Even with is Shuddering and jerking away in front of them. Even the Injector Flow/Power was all OK while it was obviously not.

At the last possible chance I called a Garage, (Caravelle Specialist in Hampshire) he suggested, Fuel Filter and fill it with Forte Diesel Treatment. So I tried it, and wouldnt you know for the last 10k miles, its been a dream to drive. Yes, I have changed the Fuel Filter twice now and yes its expensive, but hey its better than 1k on a clutch or 300 for a set of Sensors, Also I have been advised to stay away from Supermarket fuel. I only use BP or Shell now, for a treat it gets Ultimate or V-Max, but only if I'm towing.
 

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Hi All

New to this as only bought the T5 2.5tdi 130 LWB p.van 54 plate within the last week.

Anyway, I took it for a test drive before purchasing it everything fine, in fact pulled very well, impressed with the power actually. However got it on the motorway and it started to shudder, pretty bad shudder it seemed to be in 5th 6th between 2000&3000 revs, anything higher than 3000 I think it was still shuddering but revs kept it at bay. I pulled in pulled off again note not turning engine off it seemed to be in every gear also. 2000-3000 whilst putting load on engine. I limped at 70 in 4th doing 3000 revs + until next stop. I got out turned engine off, couple of mins later started her up all was fine pulling like a horse even 40mph in 5th no probs, got on motorway and it started again. Anyway got home tried to show one of the boys but for it to happen I had to drive about 7 miles until engine warmed up etc for it to start, pulled over turned off engine, restarted gone again? Weird

However she is going in for a service this week ie oils etc, handbrake and disc light always on! but I will be asking them to change the wiring loom straight away, is there only one loom and is it in the rocker cover?

I hope you guys will be saviour and they say that's exactly what it was.

Cracking forum by the way.

StefT:A:
 

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Hi I have a very annoying problem with my 2004 2.5 TDI 130 bhp transporter. The van suffers from a shudder under load at approx 1500rpm, however if you change down a gear and increase revs this does not occur. It is most noticable on the motorway from approx 55 to 80 mph.
To try and rectify this I have carried out the following replacements.
New dual mass flywheel and clutch
2 new driveshafts
3 engine mounts excluding gearbox side.
full compression test to eliminate any engine problems causing a misfire under load.
5 injectors reconditioned

The wheels & tyres have been replaced with 20' and brand new tyres. (the shudder was apparent with the old wheels as well)
The engine was replaced 15000 miles ago as the van had covered 120000 and was breathing heavily, or so the previous owner was told. The only thing I suspect may be the gearbox as this has covered 136000 miles to my Knowledge.
The van has had new bottom arms drop links discs & pads shockers coil springs etc.
I am desperate for anyones help on this matter as I have run out of ideas.
Simon
I had the same problem/symptoms as yourself with the same engine. After much expense doing all the same things as yourself to remedy the problem it was eventually found to be one of the rocker assemblies, one of the rollers was completely worn. Ended up replacing injector on cylinder 2 rocker assembly and cam shaft as all were worn due to the rocker failure. I seriously don’t know how the thing was still running.
 

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