I set my end play to .003 on my rebuild. Before installing the engine, I decided to change to a lighter flywheel. Do I need to check end play again? I know it isn't a huge deal to check end play but I just found that my dial indicator is busted.

absolutely necessary!

Damn- thats what I was expecting.

do you know how to do it with feeler gauges? its not ideal but will work in a pinch...

I just tried to check end play with the new flywheel (I found an old dial indicator). With the new flywheel, I am getting zero movement. Looks like I need to change the shims. Do I have to remove the rear main seal to remove the shims? (I don't want to go back outside tonight so I figured I would just ask)

unfortunately yes, the seal has to come out to get to the shims. and remember, you need 3 shims. no more no less.

Actually, that's not entirely true. Yes the VW manuals say "3", but it's not that important that you have 3. I've used 2 in certain circumstances when the trust surface on the flywheel has been trued where 3 won't fit with absolutely no issues. Porsche 356/912 motors only require 2. . .

The more shims you have, the less wear on the bearing so it's best to have 3, but 2 will do as long as the clearance is .003-.005".