Audi Workshop Service and Repair Manuals

Adjusting differential The differential must be readjusted when the following components have been renewed: t  Gearbox housing t  Clutch housing t  Differential cage t  Tapered roller bearings for differential

Special tools and workshop equipment required

t	End plate -VW 385/17-

t	Universal dial gauge bracket -VW 387-

t	Thrust plate -VW 401-

t	Thrust plate -VW 402-

t	Press tool -VW 408 A-

t	Press tool -VW 412-

t	Thrust pad -VW 510-

t	Tube -30 - 14-

t	Tube -2040-

t	Tube -3259-

t	Wheel bearing tube -3345-

t	-1- Kukko internal puller 21/7

t  Thrust plate -30 - 205-

t  Dial gauge -VAS 6080- t  Dial gauge extension, 30 mm

Procedure –  Drive tapered roller bearing outer race (on side adjacent to final drive gear) into gearbox housing.

–  Press tapered roller bearing outer race (on side opposite final drive gear) without shim into clutch housing. –  Install differential in gearbox housing. –  Install clutch housing and tighten 5 bolts to 5 Nm.

–  Set up measuring tool and dial gauge (3 mm measuring range, dial gauge extension -A- approx. 30 mm). –  Preload dial gauge to 1 mm and set to „0“. –  Move differential up and down and note play indicated on dial gauge (in this example: 0.50 mm). Determining thickness of shim S2 The specified bearing preload is achieved by adding a constant value (0.30 mm) to the measured value to obtain the required thickness for S2. Example:

Measured value	0.50 mm
+ Preload (constant value)	0.35 mm
Thickness of shim =	0.85 mm

–  Take off clutch housing and press out tapered roller bearing outer race -A-. B -  Internal puller 46 … 58 mm, e.g. Kukko 21/7 –  Fit shim S2 of determined thickness (in example, 0.85 mm). For part number, refer to → Electronic parts catalogue. –  Press tapered roller bearing outer race into clutch housing again. The following shims are available:

Thickness of shims in mm → Remark
0.65	0.85	1.05	1.25
0.70	0.90	1.10	1.30
0.75	0.95	1.15	1.35
0.80	1.00	1.20	1.40

1)  Different shim thicknesses make it possible to obtain the exact shim thickness required; if necessary, fit 2 shims. –  Install clutch housing and tighten bolts to final torque. Tightening torque → Chapter