I can turn it manually, turning the grey gear that also turns the trip(trip sticks a little when the 10 turns). When I turn the brass gear on the side, nothing else turns. Any suggestions for a home fix or do I need a pro?

Look in the diesel discussion... I think there might even be a link there for fixing this common problem.

Follow this link to the DIY diesel pages in the diesel discussion.
http://www.peachparts.com/shopforum/showthread.php?t=86871

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09 Jetta TDI
1985 300D

Thank you Larry! I found a link there to dieselgiant.com repair section. It describes the exact problem w/ my odo and how to fix it! I will give it a shot and post how it works out.

Takes some patience, and good lighting, but works like a charm. I have put about 200 miles on since the fix.

how do you get the loctite down between the shaft and the gear?
i could not seperate the brackat enough.
looking for suggestions.
thanks
cliff

At best, you will get less than 1/16" separation between the gear and the bracket(don't bend the bracket!). I work in a laboratory, so I used an old syringe(non-hypodermic) w/ a needle to get the locktite in where it needs to go. You could probably buy an insulin syringe cheaply at your local pharmacy that would work nicely. Also, when you are ready to do the locktite, turn the odo so that the brass gear outside the bracket is facing up (so the locktite will run down). I got a little bit between the shaft and the bracket, but that was easily broken by turning the gear. Good luck!

Mark