I had this clinging sound from behind when driving at really slow speed.
Since the VC is the most important and most expensive part in the
drivetrain, I realized the problem must be there. :-]

Yes, one of the XZN screws from the incoming drive shaft was broken and
was tumbling in the "cup" that the rubber shield makes. At higher speed
the centrifugal force kept the screw from tumbling around in there.

I tried everything to get the little part out from the thread, Ridgid
screw extractors combined with heat from the gas welding equipment. What
happened then was: the thread in the VC is an insert thread and was
coming out with the little remain part. Some of the silicon fluid
sippered out, but no big amounts. I screwed in the insert thread again,
(quickly). But I didnt get the small remain part of the screw out, so
its still there. Only two screws keeps now the incoming shaft in place.

Think about this, when working with the VC, make sure that the insert
thread are not moving with the screw. Eventually I would need a new VC
soon.

BTW, the silicon fluid looked like moly grease, and had about the same
consistense with a little overpressure in the housing. Guess the
pressure is not so high in the VC when its "unlocked". A new VC is $1375
in Sweden.

Strange that VW dont have the VC as a exchange part? Is it unrepairable?
New sealings, maybe the discs and the silicon fluid? A few ounces?

Thats my 200000 Italian Lira opinion worth! Happy holiday to all of you
syncro owners!

--
Peter Larsson
1994 Eurovan Doublecab Diesel Syncro
Sweden

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