<4ks> '85 Differential Failure @ 93K mi.

[Charles Huckleberry <charles@carl.a-com.com>]

I am looking to compare notes with those of you out there in net.world.

We have a 4000S (2wd) 'in the shop'.  Actually, it is 'back in the shop'.

VWs had served us very well for the last 30 years and the
Mother_of_all_Golfs was mortally wounded over a year ago prompting a search
for and purchase of a wonderful 4000S w/93K.  Soon after purchase last
Summer, we had a fluid leak at the Speedometer cable entry to the Auto- or
so I thought, since the Speedo went South soon after I saw the fluid there &
drops on the concrete. 'The Shop' reported that the speedo was broken- had
that fixed. 'The Shop' (an import specialty place here in Indianapolis)
reported that they had to remove the Auto to find the leak.  They looked
around and decided the non-German (knockoff) torqueconverter was OK.  BUT,
the 4K needed new seals on the FinalDrive AND AutoTrans with new fluid all
around.  Actually, they said the brake fluid looked 'really bad'.  So, I had
them make the repairs.

Five thousand miles later, as I was backing down from 80MPH (legally, I
assure you), a howling noise appeared.  It was unrelated to engine speed and
didn't occur at low speeds.  Soon, I understood this was the Differential having
problems.

We took it back to 'The Shop'.  They said the brake fluid looked 'really
bad' and insisted we change it (untill I reminded them they already DID that
quite recently- the brake fluid is fine in my estimation).  They diagnosed
the situation as a 'planetary gear pinion shaft' problem.  Soon, they were
describing that this was not_that_common.  They said the gear would cost
$1100(US) and installation would run 8 hours at $47/hr. 'PLUS anything we
find broken along the way'.  I looked for a rebuildable or rebuilt Diff for
a couple days and found them scarce _BECAUSE_ this is a common problem.
[Interesting]

Eventually, I was granted an audience with the Shop owner.  He described
that the $1100 was for an exchanged Diff. and the 8 hours were needed to do
all the work. [Interesting]

This contrasted the 3 hrs they spent removing the Diff./Auto to get to the
seals last time.  [Interesting]

Not only was the Diff sick, but I was missing the right 'sub-frame bolt'.
(My respose was !WHAT!)  This is the somewhat large bolt that holds the
'sub-frame' (with all the engine & anti-roll bar mounts up front) to the
rest of the car.  I had a rare & strange clunk sound, but didn't expect this.
[VERY interesting]

My take on the actual problem is that something was done wrong when the
seals were serviced.  Right now, I have it in an actual transmission shop
with a trans tech. experienced in German stuff.  THEY have the same request
from me as 'The Shop' got the first time around- find out what is wrong &
fix it (no compromises, just do it right).  Prelim. diag. says the Diff AND
Auto are sick.

------- UPDATE-
 Trans shop just called.  Torqueconverter filled with metal from fluid. 
Trans. needs 3 clutches, a band, and other stuff ($1100 w/T.C.)  Diff needs 
Pinion shaft & 2 bearings ($1500+).

Mind you that this trans should have been torn down last year.
They said there is a 'split ring' missing in the Auto. 
(an infamous circlip?)
Don't split rings last more than 5000mi?
------ THAT IS ALL-

Has a similar failure happened to anyone else?  I was supposed to have Synthetic
in the finaldrive- could the wrong juice here have caused such a quick failure? 
Has anyone out there had a trans inspection and repair followed by diff failure?

My first choice is to reuild the Auto and mate it with a low mile used Diff 
(about $450 w/ trans here) & rebuild my 'core' for when the used one fails.

Any & all comments welcome.

-----charles@carl.a-com.com-----------------------------------------------------
Obligatory Quattro stuff:  My brothers were saved by the Quantum they
were driving.  The '87 wagon was T-Boned by an '81 Chevy Malibu wagon going
about 50MPH.  The Q was spun 240deg - pushed 48 feet and tossed onto an 
8" curb.  The other driver couldn't believe they walked away.
--------------------------------------------------------------------
Tacitly looking for a good AUDI 4000 coupe.
CHARLES@carl.a-com.com (or @graber.a-com.com)
heredershmeredeyformbardifshkidooyaybardershnerderfnerfdhere- T.S.S.