Audi Workshop Service and Repair Manuals

Adjusting differential   Note t  The differential must be re-adjusted when the following components have been renewed: t  Gearbox housing, clutch housing, differential cage and taper roller bearing for differential. t  Table of adjustments → Chapter

Special tools and workshop equipment required

t	Universal dial gauge bracket -VW 387-

t	Measuring device d = 50 mm -VW 385/17- from universal measuring device -VW 385-

t	Press tool -VW 408 A-

t	Press tool -VW 407-

t	Thrust plate -VW 401-

t	Thrust plate -VW 402-

t	Tube -VW 415 A-

t	Press tool -VW 433-

t	Thrust plate -VW 447 H-

t	Installing sleeve -VW 455-

t  Dial gauge -VAS 6080- t  Dial gauge extension approx. 30 mm

Procedure –  Press taper roller bearing outer race (on side adjacent to final drive gear) with shim „S1“ (1 mm thick) into gearbox housing.   Note The tapered roller bearing inner and outer races are paired. Do not interchange.

–  Press tapered roller bearing outer race (on side opposite final drive gear) without shim into clutch housing. –  Install differential in gearbox housing. –  Mount the clutch housing and tighten the 5 bolts to 25 Nm.

–  Set up the universal dial gauge holder -VW 387- and dial gauge -VAS 6080- (3 mm measuring range) with dial gauge extension approx. 30 mm. A -  Shim „S1“ = 1 mm thick –  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. l  Measurement in following example: 1.50 mm.   Note Do not turn the differential during measurement as otherwise the bearings will settle and the measurement result will be biased. Determining shim „S2“ Formula: Thickness of shim = measured value + preload

Example:
Dial gauge reading (example)	1.50 mm
Preload (constant value)	+ 0.30 mm
Thickness of shim „S2“	= 1.80 mm

–  Determine the thickness of the shim on the basis of the following table; for part numbers refer to → Electronic parts catalogue.

Available shims - Thickness of shims in mm 1)
1.00	1.75	2.15
1.40	1.80	2.20
1.45	1.85	2.25
1.50	1.90	2.30
1.55	1.95	2.35
1.60	2.00	2.40
1.65	2.05
1.70	2.10
l  1) Different shim thicknesses permit precise setting of the required shim thickness. Fit 2 shims if necessary.

–  Detach the clutch housing and press out the taper roller bearing outer race. –  Fit a shim „S2“ of the thickness determined (1.80 mm in the example) and press the taper roller bearing outer race back into the clutch housing. –  Fit clutch housing and tighten bolts to 25 Nm.