On Wed, Feb 2, 2011 at 2:37 PM, Aaron <a.robinson.lists@gmail.com> wrote:
>
> I'm not sure where the differential adjuster is so this is assuming it's sealing something inside of where the drive flange oil seal sits. Excuse the ignorance, but wouldn't the oil seal keep gear oil from leaking out the drive flange area from behind the plastic cap? Is there something else that I should have replaced while "in there".
>
The differential adjuster (ETKA calls it "support ring for
differential") is the large aluminum piece that you see when you
remove the large black plastic retainer.  In the attached graphic (not
visible on the Vanagon list) it is part number 18.  The o-ring is #19,
VW part 002 301 185 A.  The drive flange seal that you have already
replaced is #20.  If you unscrew the support ring a few threads, you
can replace the o-ring that fits in the outermost groove around its
circumference.  The critical part of this procedure is to scribe a
mark across the transmission case and differential adjuster to enable
you to return it to the precise position where it was before you
touched it.  You must carefully count the turns when loosening, and
just as carefully count them when tightening.  Of course, you must
replace the drive flange seal and disc (again) when doing this.  If
you're handy, you can fabricate a tool to loosen the differential
support ring.  I purchased a tool for $90 (Long Enterprises, I think)
and consider it money well spent.  A word of warning:  If you do this
wrong, the next step is a very expensive transmission rebuild.  I have
driven about 3000 miles since replacing one of mine and the only
noticeable difference is the absence of the previous oil leak.

-- 
Michael Snow
1987 Syncro TiiCo
1982 Westfalia 1.9TD
http://slowmachine82.blogspot.com/