Volkswagen Workshop Service and Repair Manuals

The differential must be adjusted, when

• ◆ Gearbox housing
• ◆ Clutch housing

• ◆ Differential housing

or the

• ◆ Differential taper roller bearing

have been renewed.

Adjustment overview .

• ‒ → Press taper roller bearing outer race (gear wheel side) with shim S1 (always 1 mm thick) into gearbox housing.

Note:

Taper roller bearing inner and outer races are paired. Do not interchange!

• ‒ → Press taper roller bearing outer race (opposite gear wheel side) without shim into clutch housing.

• ‒ Fit differential into gearbox housing.
• ‒ Fit gearbox housing and tighten 5 bolts to 25 Nm.
• ‒ → Assemble measuring device and D.T.I. (3 mm measuring scale, approx. 30 mm extension).

•      A -     Shim S1 = 1 mm thick

• ‒ Zero D.T.I. with one 1 mm preload.
• ‒ Move differential up and down, read and note play indicated on D.T.I.
  (Example: 1.50 mm)

Note:

Do not turn differential when measuring, otherwise the bearing will settle and a false measurement will be given.

Determining shim S2 thickness

The specified bearing preload is obtained by adding a constant figure (0.30 mm) to the reading obtained for S2 (example: 1.50 mm).

Example:

• ‒ → Remove clutch housing and drive out taper roller bearing outer race.
• ‒ Fit determined S2 shim (in example 1.80 mm) and press taper roller bearing outer race again into clutch housing.
• ‒ Assemble clutch housing and tighten bolts to 25 Nm.

The following shims are available:

→ Checking friction moment

A - Commercial torque gauge 0 ... 600 Ncm

B - 13 mm socket insert

For new taper roller bearings the friction moment must be 120 ... 250 Ncm.

For used taper roller bearings the friction torque must be at least 30 Ncm.

Note:

Lubricate bearings with gearbox oil before checking friction moment.