Passat Sedan L4-1.9L DSL Turbo (AAZ) (1995)
Front Final Drive: Adjustments
Adjustment of the differential is necessary if any of the following components is replaced:
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Transmission housing
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Clutch housing
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Differential housing
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Differential tapered roller bearings
Adjusting
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Press tapered roller bearing outer race into clutch housing without adjustment shim, using 30-205 thrust pad
CAUTION: Tapered roller bearing inner and outer races are a matched pair. DO NOT interchange.
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Press tapered roller bearing outer race into transmission housing without adjustment shim, using 3~205 thrust pad
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Install differential in clutch housing
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Install transmission housing with 5 bolts and tighten
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Tightening torque: 25 Nm (18 ft lb)
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Install dial indicator with mounting fixtures as shown. Set indicator to zero with 1 mm preload
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Move differential gear up and down, observe and record play on dial indicator
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Example: measured play = 0.70 mm
CAUTION: Do not rotate the differential while making a measurement, as this will cause the bearings to settle and result in a false measurement
Calculating Adjustment Shim Thickness
The correct shim thickness is selected by adding:
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specified bearing preload (a constant, 0.40 mm)
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The measured axial play (example: 0.70 mm)
Example:
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Add Measured play (example) 0.70 mm
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Plus Preload (constant) 0.40 mm
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Required shim thickness = 1.10 mm
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Remove transmission housing
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Pull out bearing outer race or drive out using VW 473 thrust pad
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Install adjustment shims of the correct thickness
NOTE: When using two shims, install thickest shim first.