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6-Speed manual gearbox 02M, Front-wheel drive > < Dismantling and assembling differential

A3 Mk1

Adjusting differential
   
Adjusting differential
Special tools and workshop equipment required
t  End measuring plate -VW 385/17-
t  Universal dial gauge bracket -VW 387-
t  Press tool -VW 407-
t  Thrust plate -30 - 205-
t  Torque wrench -V.A.G 1331-
t  -1-Internal puller -Kukko 21/7-
t  -4-Counter-support -Kukko 22/2-
t  Dial gauge

It is necessary to readjust the differential when the following components have been renewed:
t  Gearbox housing
t  Clutch housing
t  Differential cage
or the
t  Differential tapered roller bearings
Table of adjustments → Chapter
  Note
The tapered roller bearing inner and outer races are paired. Do not interchange.
–  Press tapered roller bearing outer race into clutch housing using thrust plate -30 - 205- → Fig..
–  Press tapered roller bearing outer race without shim into gearbox housing using thrust plate -30 - 205- → Fig..
–  Install differential in clutch housing.
–  Place gearbox housing in position and tighten 5 bolts to 25 Nm.
   
–  Attach dial gauge and set to “0” with a preload of 1 mm.
–  Move differential up and down and read off and note play indicated on dial gauge. (0.85 mm in this example.)
Determining thickness of shim
The specified bearing preload is obtained by adding a constant figure (0.25 mm) to the reading indicated.
Example:
  V39-1278
Measured value0.85 mm
+ Preload (constant value)0.25 mm
Thickness of shim =1.10 mm

   
–  Detach gearbox housing and pull tapered roller bearing outer race out of gearbox housing.
A - Counter-support, e.g. -Kukko 22/2-
B - Internal puller 46 ... 58 mm, e.g. -Kukko 21/7-
–  Install shims of the calculated thickness, thickest shim first.
  N39-0026
 Shim
Measured value (mm)Thickness (mm)
0.303…0.449
0.450…0.499
0.500…0.549		0.650
0.700
0.750
0.550…0.599
0.600…0.649
0.650…0.699		0.800
0.850
0.900
0.700…0.749
0.750…0.799
0.800…0.849		0.950
1.000
1.050
0.850…0.899
0.900…0.949
0.950…0.999		1.100
1.150
1.200
1.000…1.049
1.050…1.099
1.100…1.149		1.250
1.300
1.350
1.150…1.1991.400

If the size of the shim required is larger than those listed in the table, install two shims amounting to the correct value.
Tolerance variations make it possible to obtain the exact shim thickness required.
  Note
Select correct shims from → Electronic parts catalogue.
–  Press in outer race of differential tapered roller bearing again and secure gearbox housing → Fig..
   

6-Speed manual gearbox 02M, Front-wheel drive > < Dismantling and assembling differential