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02Berry Samba Member

Joined: May 08, 2022 Posts: 60 Location: Tacoma, WA
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Posted: Fri Jul 11, 2025 12:04 pm Post subject: Re: Tool Kit (suggestions) for Road Trip |
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Things we needed on the last big road trip:
10mm nut & washer for the sliding door rail.
Taillight bulb.
Trim tools (for pushing the beading back into the tent mounting channel, also for removing passenger door panel).
Screwdrivers.
10mm wrench.
Allen wrench(es). Not sure of size, but metric, of course.
18" length of rebar to insert in the lug wrench for added torque when removing wheel nuts.
Headlamp (for wearing while peering into the dark places at inconvenient times).
Box of nitrile gloves.
Rags/paper towels.
lubricant for the window regulator/tracks.
[Oh yeah, we also had to replace the radiator fans, but for us, that was a matter of taking it to a shop.]
We also needed to wash our windshield now & then, especially in insect-rich places -- I mean, the wipers do their job, but for travel enjoyment, a fully clean windshield is really nice.
And I'll ditto the GoWesty pre-programmed Scangauge, for watching transmission oil temp. (We already have their transmission oil cooler installed) _________________ Learned to drive in a '67 Splitty.
First car, '72 Squareback.
New to '02 T4 EVW world.
Third generation VW camper household. |
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lavabiscuit Samba Member
Joined: June 29, 2016 Posts: 5
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Posted: Fri Jul 11, 2025 4:20 pm Post subject: Re: Tool Kit (suggestions) for Road Trip |
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Thanks for the great tips! I feel very well informed from reading these forums.
I unfortunately had my first mechanical issue already. Driving from picking up the van to the eastern Sierra I had some serious overheating. The radiator fans weren’t running unless the AC was on (saw this mentioned in a post here.) I was able to get it to Tim Miller at Sierra German Auto, and he traced it to a bad sending unit which is on order now.
Here is a picture at the mechanic’s. Funnily enough, there was another Eurovan with fan problems there at the same time.
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67rustavenger Samba Member

Joined: February 24, 2015 Posts: 11015 Location: Oregon
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Posted: Fri Jul 11, 2025 5:21 pm Post subject: Re: Tool Kit (suggestions) for Road Trip |
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My 03 EV had the same failure, before I bought it.
A mechanic in Mt. bypassed the trans cooler when he "so called repaired" the cooling fans.
The end result was, a complete transmission replacement with a different trans due to it completely welding all the internal goodies together. It wasn't pretty and it was, Expensive to replace.
It's rude but, if you can, keep a sharp eye on the mech. while he does the repair on your EV. You don't want to go through what the PO of my van did. _________________ I have learned over the years.
Cheap parts are gonna disappoint you.
Buy Once, Cry Once!
There's never enough time to do it right the first time. But there's always enough time to do it thrice.
GFY's Xevin and VW_Jimbo!
2003 Astrovan? GFYS again, Xevin!  |
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Endopotential Samba Member

Joined: February 13, 2012 Posts: 291 Location: Just outside SF, CA
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Posted: Fri Jul 11, 2025 10:47 pm Post subject: Re: Tool Kit (suggestions) for Road Trip |
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A bit of thread digression, but...
Lavabiscuit - sorry you're getting to bond with your new van in such fashion.
While you're at it, replace these green resistors which are found underneath the front bumper. They help control the speed of your radiator fans. They're often corroded after 20 years and cheap and easy to replace. You'll need 2 of them
https://www.amazon.com/ROEDE-701959263D-Resistors-...8&th=1 _________________ 2002 Eurovan Weekender |
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lavabiscuit Samba Member
Joined: June 29, 2016 Posts: 5
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Posted: Sat Jul 12, 2025 4:25 am Post subject: Re: Tool Kit (suggestions) for Road Trip |
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Thanks, I was wondering about that. I’ve heard that when they go, it can be pretty bad. Will do it!
Endopotential wrote: |
A bit of thread digression, but...
Lavabiscuit - sorry you're getting to bond with your new van in such fashion.
While you're at it, replace these green resistors which are found underneath the front bumper. They help control the speed of your radiator fans. They're often corroded after 20 years and cheap and easy to replace. You'll need 2 of them
https://www.amazon.com/ROEDE-701959263D-Resistors-...8&th=1 |
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lavabiscuit Samba Member
Joined: June 29, 2016 Posts: 5
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Posted: Sat Jul 12, 2025 8:57 am Post subject: Re: Tool Kit (suggestions) for Road Trip |
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Sorry, another question. Might as well keep it in this thread I guess.
I was practicing a tire change to make sure I had what I needed and knew how to do it. Good thing, because I can’t get the freaking wheel back on. I can get it up to where the center of the rim hangs on the part of the hub that sticks out, but it won’t go all the way on. There is still a large gap between the wheel and the hub. So even though the bolt aligns with the hole, it doesn’t reach. I’ve just learned about wheel hangers, and I’m definitely going to get one, but even with the wheel close to where it needs to be, I can’t get it that last half inch in. Any suggestions? Thank you! |
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67rustavenger Samba Member

Joined: February 24, 2015 Posts: 11015 Location: Oregon
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Posted: Sat Jul 12, 2025 11:54 am Post subject: Re: Tool Kit (suggestions) for Road Trip |
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lavabiscuit wrote: |
Sorry, another question. Might as well keep it in this thread I guess.
I was practicing a tire change to make sure I had what I needed and knew how to do it. Good thing, because I can’t get the freaking wheel back on. I can get it up to where the center of the rim hangs on the part of the hub that sticks out, but it won’t go all the way on. There is still a large gap between the wheel and the hub. So even though the bolt aligns with the hole, it doesn’t reach. I’ve just learned about wheel hangers, and I’m definitely going to get one, but even with the wheel close to where it needs to be, I can’t get it that last half inch in. Any suggestions? Thank you! |
It's a bit fiddly to get the wheel remounted on the rotor.
I recently rotated my tires and all but one went on easily. For whatever reason the final wheel refused to mount correctly but, I was able to get the lug bolts into the rotor. Once the wheel was mounted and the lug bolts were in, I lowered the van back down until just touching the ground and realigned the wheel to the rotor. Fiddly!
Sorry to say it but, you're gonna just figure it out, and yeah that mounting stud may be just the thing to help get the wheel aligned with the rotor correctly. _________________ I have learned over the years.
Cheap parts are gonna disappoint you.
Buy Once, Cry Once!
There's never enough time to do it right the first time. But there's always enough time to do it thrice.
GFY's Xevin and VW_Jimbo!
2003 Astrovan? GFYS again, Xevin!  |
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jjvincent Samba Member
Joined: January 11, 2016 Posts: 1422 Location: Bethlehem, PA
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Posted: Sun Jul 13, 2025 12:38 pm Post subject: Re: Tool Kit (suggestions) for Road Trip |
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lavabiscuit wrote: |
Sorry, another question. Might as well keep it in this thread I guess.
I was practicing a tire change to make sure I had what I needed and knew how to do it. Good thing, because I can’t get the freaking wheel back on. I can get it up to where the center of the rim hangs on the part of the hub that sticks out, but it won’t go all the way on. There is still a large gap between the wheel and the hub. So even though the bolt aligns with the hole, it doesn’t reach. I’ve just learned about wheel hangers, and I’m definitely going to get one, but even with the wheel close to where it needs to be, I can’t get it that last half inch in. Any suggestions? Thank you! |
Buy two M14X1.5 threaded rods from Amazon. If not that, cut a long one in half. Thread them into two of the holes and then use them as a guide to get the wheel on. Install some lug bolts, remove the threaded rod and replace with remaining lug bolts.
Some Audi's and VW's come with a plastic one in the toolkit. I have found just getting threaded rod works just fine and is cheap. You can do it with one but having two just makes it a bit easier. Thus doing it on the side of the road, you want it as easy as possible.
Also, put antisieze or grease on the centering hub and the centering hole on the wheel. This way corrosion won't freeze the wheel on or make the other one hard to install. |
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WorthaTry Samba Member
Joined: June 12, 2025 Posts: 20 Location: Dryden, NY
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Posted: Mon Jul 14, 2025 7:17 pm Post subject: Re: Tool Kit (suggestions) for Road Trip |
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A week or so after I got my EV home it occurred to me to check and make sure it has a jack. You know, just in case. After not finding it I consulted the manual and discovered I had to remove the bed platform to get to it. Rummaging around in the cubbies that revealed I found the jack, a collapsible tire cross lug wrench, and a variety of items one might want in case of road emergency, or at least one might receive for Christmas from someone wanting to give you something for your cool van. The potentially useful items of interest that I wasn't expecting were a tow strap, and a tow hook designed to be inserted into the receiver hitch. Those might actually be worth adding to the Road Trip Took Kit list.
After reading about the tire changing challenge I checked again today to see if by chance there were any wheel hanger pins, but alas, no. Here's the Amazon link if anyone else needs them: https://www.amazon.com/Steel-Wheel-Hanger-Alignment-Guide/dp/B07SFKHGTR _________________ 2001 EV MV Wk |
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