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Discussion Starter #1
Hello (sorry, re-posting here as I think I put it in wrong thread)

I've a 2005 T5, 2.5 diesel, 6-speed auto with about 190,000 km. I've had it since new and it has full VW service history. Never had any work done on gearbox.

Recently it started making clunky changes (you feel the car shudder and hear a thump noise) going both up and down the box, mostly in lower gears. Yesterday it made a distinctive thump/shudder every time going into Drive from Reverse or neutral (with car stopped and engine idling). Today this doesn't happen so badly, but still it isn't as smooth as before. I think it never happens when the car is cold. In general it's slowly getting worse...

Any advice?

Thanks!
 

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There a good chance it's one or both of the driveshafts if it is related to the gear box and changing gear. They are a common week spot on the T5. But, it might be worth looking under at all the suspension bushes, loose moving parts can clunk away merrily, especially if none have been changed along with the high mileage. (Just had to change the strut top bearing on mine as they clunked when I had to select gear to reverse up an incline.)

I do doubt that it is a problem with the auto box though. You would more than likely get delayed gear engagement, almost like a slipping clutch feeling if the box was playing up.

I still think it's driveshafts though in how you describe it.
 

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Even if its driveshafts, at 190K I'd be looking at changing gearbox oil and filter at that sort of mileage.

I did it on my old Beemer 740i at 170,000 miles and the gearbox felt like new afterwards. BMW's idea of the definition of "life" in a "sealed for life" gearbox, differs greatly from mine. ;)
 

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Even if its driveshafts, at 190K I'd be looking at changing gearbox oil and filter at that sort of mileage.

I did it on my old Beemer 740i at 170,000 miles and the gearbox felt like new afterwards. BMW's idea of the definition of "life" in a "sealed for life" gearbox, differs greatly from mine. ;)
Totally agree, sealed for life!?! What ever VW!!
Get mine serviced every year, about 50k and well worth £150
 

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In the the past ours has slipped and banged into gear when changing up. It did it twice on a journey and frightened the life of me.

Have since had the oil changed and it's never done it again.

Dan's comments about driveshafts are worth looking into.
 

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Discussion Starter #7
Updating here:

Finally got the gearbox oil changed. Made no difference. VW garage here (Dutch speaking) say it may be the 'regelkast', which translates as 'rule box' or probably 'control box'. And it's not a cheap fix... ;-)

I'm sure it's not a driveshaft/suspension/etc issue. It bangs into gear mainly downshifting from 5-4-3, but can be in lower gears too (only when warm, i.e. after 20 mins driving).

Thanks for any further thoughts...
 

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Hi, ive had something similar recently, but it was clunking on the gas and off the gas. Mechanic thinks its the bottom engine mount. Hopefully getting it fixed this week, hes been very busy.
 

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Discussion Starter #9
Posting for info - the problem has been identified by two garages to be the gearbox valve body. Replacing is going to be about £1500. Will update with news ...
 

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Posting for info - the problem has been identified by two garages to be the gearbox valve body. Replacing is going to be about £1500. Will update with news ...
Please do, update, these auto boxs are quite complex and it would be useful to have 'Fixed' problem on here.

Mine has started not fully engaging 3rd and sometimes 4th now until the gear box has warmed up for 5 mins. After that it engages fine.
 

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Discussion Starter #11
I will update, but it will be a few weeks.

With mine, at the moment it works fine when cold and fully hot, but short journeys 20-40 mins in cold weather are when symptoms happen. Seems likely because of sticking solenoids, though the VW plug-in test didn't detect anything. Maybe I should've changed the oil earlier, though the specialist transmission guy said these are common faults after high mileage irrespective of oil change.

Links with info (scroll down)

http://www.carparts.com/transmission.htm
https://cartreatments.com/valve-body-functions-and-symptoms/
 

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I had the valve body replaced on my 2005 t5. It failed after about 8 thousand miles after it was reconditioned.
It was its last owner who paid for this.

When I bought the van I didn't realise that the gearbox was not working properly, it was when I was having an exhaust fitted that the guy there told me that it should be smoothly changing between first and reverse. I assumed that they all jumped a bit.

Anyway, the receipt for the rebuild was in the documents that I received with the vehicle. Unfortunately the warrenty had run out the month before I checked it.

I contacted the gearbox repair place on the warranty anyway, and a very friendly guy said that if I brought it in he would repair the throttle body at cost to help me out. At £950 it was still quite something but what could I do? And I doubt I would ever get such a generous offer again. When I arrived they were all very friendly and finished it while I went into town and back.
It is now much smoother (but nothing like as slick as the ancient Mazda bongo I had).
 

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Discussion Starter #13
Promised I'd update: Yesterday gearbox valve body replaced. Problem solved. Thoroughly advisable for anyone with similar issues, as driving with the box banging through gears ad for whole drivetrain. Now feels like new.
 

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Out of interest, how much did it cost and where did you get it done? Mine has always been fine but nothing lasts forever.....
 

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Discussion Starter #16
I live in Europe, not UK. Total (incl parts & labour) probably will be ~1500 euros. Note the valve body is new. Could have gone for reconditioned but weren't any available...
 

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Thanks for posting the solution..

I also have an auto LHD T5 Multivan (2009 2.5 7HM) with a similar clunk changing down 3rd to 2nd and 2nd to 1st. Only happens in cold weather, and then only rarely. nevertheless, I do plan to get it fixed. I also spend a lot of time in Belgium/NL (I gather you live around there).. While trying to figure out next steps, I found a specialist Auto Box repair company called Autrans with outlets in Lunteren and Tilburg.

http://www.autrans.nl/

Just posting because I have visited Autrans and it seems a high quality shop.. I'll probably take my van there for the Valve Body replacement..
 

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Discussion Starter #18
Thanks, yes I live in Belgium. I used my VW dealer because after a few quotes seemed all were comparable, and they know the van
 
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