WELL! i'd like to thank all on the list for the sound advice. After talking
to some helpful gentlemen at various vw rebuilders, i determined that my
problem is most likely the pinion shaft 'double tapered bearing'. so, i have
a pretty complete rebuild kit(including about $400 just in tools) on the way
from long enterprises and i'm getting myself psyched up to get all up in
some dang gearbox! WOO!

so here's a good discuss-o-question: what kind of setup do you use to
support the engine while the trans is out? i have to roll the van out of the
shop while i work, and i'm sure i'll figure something out but do you folks
have any super cool, non-obvious tricks? is it worth it to fabricate
something like the tool shown in the bentley manual? it doesn't seem like
there will be all that much weight to support, will there?(my van is diesel)

updates/pictures to come
thanks again, dudes
-bob