Audi Workshop Service and Repair Manuals

Adjusting differential

Special tools and workshop equipment required

t	End measuring 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-Internal puller 46...58 mm, e.g. -Kukko 21/7-

t  Thrust plate -30-205- Adjusting The differential has to be readjusted when the following components are renewed: t  Gearbox housing t  Clutch housing t  Differential cage or the t  Tapered roller bearings for differential

To gearbox build date 05 05 2 –  Press tapered roller bearing outer race (gear wheel side) with shim S1 (always 1 mm thick) into gearbox housing.   Note The tapered roller bearing inner and outer races are paired. Do not interchange.

From gearbox build date 06 05 2 onwards –  Press tapered roller bearing outer race (gear wheel side) with shim S1 (always 1 mm thick) into gearbox housing. Continued for all gearboxes

–  Press tapered roller bearing outer race (opposite gear wheel side) without shim into clutch housing. –  Install differential in gearbox housing. –  Fit clutch housing in place and tighten 5 bolts to torque → Item.

–  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 read off and note play indicated on dial gauge. (0.55 mm in this example.) Determining thickness of shim S2 The specified bearing preload is achieved by adding a constant value (0.25 mm) to the measured value to obtain the required thickness for S2. Example:

Measured value	0.55 mm
+ Preload (constant value)	0.25 mm
Thickness of shim =	0.80 mm

–  Remove 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 required thickness (in this example 0.80 mm) and press tapered roller bearing outer race back into clutch housing. The following shims are available:

Thickness (mm)	Part number
0.65 0.70 0.75	02K 409 210 02K 409 210 A 02K 409 210 B
0.80 0.85 0.90	02K 409 210 C 02K 409 210 D 02K 409 210 E
0.95 1.00 1.05	02K 409 210 F 02K 409 210 G 02K 409 210 H
1.10 1.15 1.20	02K 409 210 J 02K 409 210 K 02K 409 210 L
1.25	02K 409 210 M

Tolerance variations make it possible to obtain the exact shim thickness required. If the size of the shim required is larger than those listed in the table, install two shims amounting to the correct value. –  Fit clutch housing in place and tighten bolts to torque → Item.