So having checked for continuity from vss plug to speedo plug and getting a good connection, plus getting a good 12 v at the vss plug, I'm left with two options, broken vss, or cluster 
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1991 S2 3B Coupe, KW v1, solid sub frames, poly bushed, chipped, about 260 ish
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Well it could be the cluster but since you tried another cluster and there was no improvement, you probably need to replace the 012409191D VSS sender. There are a number of options, e.g. Audi dealer, Pete at quattrocorner, etc. and ebay.co.uk:
http://www.ebay.co.uk/sch/i.html?_fr...9191D&_sacat=0
Prices vary.
RS2'd 93 UrS4 5 spd sedan
94 UrS4 V8 6 spd manual avantComment
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How did you rule out the sender ring?Comment
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At least I'm confident it's not wiring, or a corroded plug1991 S2 3B Coupe, KW v1, solid sub frames, poly bushed, chipped, about 260 ishComment
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By buying and installing the VSS sender to see if that it the issue first. The sender ring, item 8 below, well inside the left drive flange and would be a major transmission out of the car replacement task and besides, when is the last time you heard of one failing (NEVER).
RS2'd 93 UrS4 5 spd sedan
94 UrS4 V8 6 spd manual avantComment
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Well I had it changed in mine (the problem was in vss anywayBy buying and installing the VSS sender to see if that it the issue first. The sender ring, item 8 below, well inside the left drive flange and would be a major transmission out of the car replacement task and besides, when is the last time you heard of one failing (NEVER).
) but the problem was too intermittent to be easily identified.
You do not need to remove the box. Just remove DS axle, drain the oil and remove the side cover with CV flange.
Not a common problem, but i know it has happened before.Comment
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So you could have save the time and money and NOT gone to the effort of replacing the 012409187C sender ring by just replacing the G22 012409191D sender. That said, it is good to know that the transmission doesn't have to come out to see and replace the sender ring, as shown below. I will add this info and your comments to my G22 info post.Well I had it changed in mine (the problem was in vss anyway ) but the problem was too intermittent to be easily identified. You do not need to remove the box. Just remove DS axle, drain the oil and remove the side cover with CV flange. Not a common problem, but i know it has happened before.
Sender ring:
RS2'd 93 UrS4 5 spd sedan
94 UrS4 V8 6 spd manual avantComment
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yes i know, but unfortunately i decided to go with the ring first, and the with the sensorComment
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Just to confuse things, the difflock is disengaging as it should, plus the trip counter is working , I'm confused now as both those get there signal from the vss, or am I wrong ?
1991 S2 3B Coupe, KW v1, solid sub frames, poly bushed, chipped, about 260 ishComment
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What happens to the VSS after the G21 speedometer
From my G22 info link that I provided previously, here is what happens to the white/blue wire output from the G21 Speedometer on a UrS4/S6 (S2 list will be similar, pins and connectors will be different):
RS2'd 93 UrS4 5 spd sedan
94 UrS4 V8 6 spd manual avantComment
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Am I right in thinking that the difflock wouldn't disengage if the vss was broken, or that the odometer wouldn't work?
And how much is a new cluster these days?1991 S2 3B Coupe, KW v1, solid sub frames, poly bushed, chipped, about 260 ishComment
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I'm still willing to swap out the vss as there so cheap,1991 S2 3B Coupe, KW v1, solid sub frames, poly bushed, chipped, about 260 ishComment
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Based on the evidence, your G22 VSS sender is fine and portions of the G21 Speedometer are also fine. It would appear that the issue is the actual speedometer not the odometer or the output from the speedometer. You don't need a whole cluster, even *IF* they were available new. Try to find a good used speedometer.RS2'd 93 UrS4 5 spd sedan
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