The manual five-speed gearbox in VW T4 vans has been prone to problems in the past, such as grinding gears and excessive wear on parts of the gearbox and the clutch. If you’re buying a used van, you should make sure it is able to handle gear changes.
Owners of later versions with a dual-clutch transmission have also reported issues such as slipping, shaking and gearbox failure.
EGR valve problems
A commonly reported problem for the T5 and T6 generations is related to the VW Transporter EGR valve. It has a tendency to get blocked up by sticky deposits and dirt, which can prevent it from opening or closing to regulate the flow of exhaust gases.
If the valve is jammed open, you may experience stalling or rough idling, as well as other performance issues. If it is jammed shut, your engine may overheat and start to knock. If cleaning the EGR valve doesn’t solve the issue, it will need to be replaced.
Drive shaft problems
Van drivers are generally advised to inspect and lubricate the drive shaft around every 40,000 miles. If there isn't a sufficient amount of oil, the splines on the shaft and other components could become worn or damaged, causing a clunking sound when driving. You should also remember to check the seals.
Security alarm malfunction
Some VW owners have reported that the alarm goes off at random times, particularly in wet conditions. It’s possible that it is triggered due to a wiring fault, such as damaged or corroded wires.
The Transporter ECU is responsible for monitoring and triggering the security alarm. You may be able to determine by connecting it to a diagnostic scanner.
Engine-related problems
If your motor struggles to start, is hissing or ticking and misfiring, it could be time for a timing belt replacement. This is usually a result of gradual wear and tear. The manufacturer recommends replacing the belt once every four years for vans produced before 2009 and every five years for those released after 2009.
Certain models have been known to develop oil pressure faults. In some cases, the low oil pressure warning light is triggered due to electrical issues caused by the alternator, however in other cases it is caused by a clogged filter, bad oil pump or oil leak. VW Transporter engine oil is important to check and change regularly and on time.
Oil leaks can occur between the manual gearbox and the engine on T5 vans due to poorly threaded holes for the bolts securing the flywheel.
Window faults
For example, there have been a number of complaints about leaky windows on the T5 in rainy and stormy weather. If the issue is not dealt with, your van may start to smell musty and mould can grow inside. Sometimes this can be solved using a good window sealant, although you may also choose to replace the factory-fitted windows.
Some people complain that the electric windows on their VW Transporter are not working properly. If there has been a leak, it’s possible that the moisture has affected the power mechanism, corroding the wires or connectors.
Defective steering column
This is a particularly common issue for T5s. Some drivers have reported a knocking or clunking sound as they turn the wheels. This could indicate a problem with the steering column. Fixing the vehicle may require a full or partial replacement.
Power steering problems
You may recognise that the van has become much more difficult to turn, requiring more effort than usual. Other symptoms may include a grinding noise when steering or a vibrating steering wheel. This is often the result of a loss of power steering fluid or an issue with the pump or Transporter steering rack.
Central locking faults
The central locking and van lighting control module can be prone to water contamination. This causes electrical faults that may prevent the lights from turning on and the locking system from working properly. Sometimes you can get away with cleaning the connections with a wire brush and an electrical contact cleaner.
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