while i was installing my new tranny in my tsi, i noticed the output shaft that goes to the transfer case would come all the way out of the tranny and would not lock back in. i thought of it as nothing and maybe when it was rebuilt the guy must have forgotten to put the ring back on. i was too scared to take the shaft all the way out, just incase i couldn't get it back in.

anyway, after getting everything back together i took it out of the garage. while i was pulling it out i heard a ticking that was the same as the wheels revolution. i parked the car and let it run. then i heard a very erractic but quiet ticking/knocking coming from the case behind the passenger side spash shield.

im thinking the ring must be in the case still and swimming around with the gears and syncros. my question is, can i get the ring out easily without removing the tranny? is it safe for me to pull the output shaft out and install a retaining ring? thanks.

Ehhh, thats an "ify" one there... You may have to drop the tranny again. I'm not completely sure about all that but I do know that my tranny did the same thing (ticking) and it went to complete shit. We drained the tranny fluid and it was completely silver with metal shavings. If it were me again, I would not drive it until its fixed properly.