Skoda Workshop Service and Repair Manuals

Adjusting the differential gear Special tools and workshop equipment required t  Gauge block plate -MP3-405/17 (VW385/17)- t  Pressure plate -MP3-407 (VW402)- t  Universal dial gauge holder -MP3-447 (VW387)- t  Pipe section -MP3-450 (VW415A)- t  Mandrel -MP3-511- t  Interior extractor -Kukko 21/7- t  Countersupport -Kukko 22/2- t  Dial gauge The differential gear must be re-set when the following components are replaced: t  Gearbox housing t  Clutch housing t  Differential gear housing t  differential gear tapered-roller bearing   Note t  New tapered-roller bearings for the differential gear are low friction. Therefore the friction torque has limited value as a control parameter. Correct setting of the bearing preload is only possible by determining the thickness of the adjusting washer. t  The inner and outer rings of the tapered-roller bearing are paired. These are not interchangeable.

–  Support the clutch housing with a pipe section -MP3-450 (VW415A)- directly below the bearing hole. –  Press the outer ring for the tapered-roller bearing into the clutch housing with the impact mandrel -MP3-511-.   Note No adjusting washer is fitted at the side of the clutch housing.

–  Press outer ring/tapered-roller bearing without adjusting washer into the gearbox housing. –  Insert the differential gear in the clutch housing. –  Position the gearbox housing and tighten 5 screws to torque 25 Nm.

–  Set the dial gauge to 0 with 1 mm preload on “0”. –  Move the differential gear up and down, read off and write down the clearance on the dial gauge. (Example: 2.30 mm)   Note Do not turn the differential while measuring as otherwise the bearings will settle and the measuring result will be inaccurate. Determine thickness of the adjusting washer The prescribed bearing preload is reached by adding to the established measured value a constant compression value (0.20 mm). Example:

measured value	2.30 mm
+ pressure (const. value)	0.20 mm
Thickness of the adjusting washer	2.50 mm

–  Remove the gearbox housing and pull out the outer ring/tapered-roller bearing from the gearbox housing. -A- Countersupport, e.g. countersupport -Kukko 22/2- -B- Interior extractor 46...58 mm, e.g. interior extractor -Kukko 21/7- –  Insert an adjusting washer of the correct thickness. –  Press outer ring in again and screw down the gearbox housing. The following adjusting washers are available:

Thickness (mm)	Spare part No.
2,0	002 409 383 A
2,1	002 409 383 B
2,2	002 409 383 C
2,3	002 409 383 D
2,4	002 409 383 E
2,5	002 409 383 F
2,6	002 409 383 G
2,7	002 409 383

Different tolerances allow to measure the required thickness for each washer very precisely.