Audi Workshop Service and Repair Manuals

Adjusting differential

Special tools and workshop equipment required

t	Universal dial gauge bracket -VW 387-

t	End measuring plate -VW 385/17-

t	Thrust plate -30-205-

t	Press tool -VW 407-

t	Dial gauge

Procedure –  Press tapered roller bearing outer race into clutch housing (without shim) using thrust plate -30-205-.   Note The tapered roller bearing inner and outer races are paired. Do not interchange.

–  Press tapered roller bearing outer race into gearbox housing (without shim) using thrust plate -30-205-. –  Place sleeve -3144- directly under bearing seat to support gearbox housing. –  Install differential in clutch housing. –  Fit gearbox housing and tighten 5 bolts to 25 Nm. –  Press differential towards clutch housing; hold in this position and turn eight times. –  Press differential towards gearbox housing; hold in this position and turn eight times.

–  Attach dial gauge and set to “0” with a preload of 1 mm. –  Move differential up and down and note play indicated on dial gauge (in this example: 0.70 mm). Determining thickness of shim Formula: Thickness of shim = measured value + preload

Example:
Dial gauge reading (example)	0.70 mm
Preload (constant value)	+ 0.40 mm
Thickness of shim	= 1.10 mm

–  Select required shim thickness from following table:

Available shims - Thickness of shims in mm 1)2)3)
0.65	0.90	1.20
0.70	0.95	1.15
0.75	1.00	1.25
0.80	1.05
0.85	1.10
l  1) For Part No. refer to → Parts catalogue. l  2) Tolerance variations make it possible to obtain the exact shim thickness required. l  3) If the size of the shim required is larger than those listed in the table, install two shims amounting to the correct value.

–  Remove gearbox housing and pull taper roller bearing outer race out of gearbox housing, or press out using thrust piece -VW 473-. –  Install shim(s) of the required thickness (thicker shim first). –  Press outer race back in. –  Tighten bolts to 25 Nm and turn 90° further.