SEAT Workshop Service and Repair Manuals

Differential: adjust

Special tools and workshop equipment required

t	Case for repairing gearboxes -U-40200-

t	Case for repairing gearboxes -U-40300-

t	Multi-purpose stand for the tester -T20020-

t	Dynometric keys -SAT 8010-

Adjust the differential when any of the following components have been replaced: t  Gearbox casing t  Clutch casing t  Differential box t  Tapered roller bearings in the differential So as to avoid unnecessary adjustment work, consult the Chart for Adjustment → Chapter.

–  Extract the outer track of the tapered roller bearing from the gearbox casing and clutch casing using tool -U-40200/10- and tool -U-40300/14-.   Note! t  The procedure and the tools needed for dismounting the outer tracks of the tapered roller bearings are the same in the gearbox casing and in the clutch casing. t  The tapered roller bearings and their corresponding outer tracks come in pairs. Do not mix them up or exchange them with other bearings.

–  Assemble the outer track of the tapered roller bearing in the differential into the gearbox casing and clutch casing using tool -U-40200/10- and tool -U-40300/12-.   Note! The procedure and the tools needed for dismounting the outer tracks of the tapered roller bearings are the same in the gearbox casing and in the clutch casing. –  Place the differential over the clutch casing. –  Assemble the gearbox casing onto the clutch casing and tighten the 5 bolts for attaching them in the area of the differential. Tightening torque: 25 Nm

–  Place the tool -T20020- with a tester onto the gearbox casing. Place the end of the tool on the differential and fit the tool -U-40300/13- between them. –  Adjust the tester to “0” with a prior stress of 1 mm. –  Move the differential alternatively in the direction of the arrows. –  Write down the reading obtained on the tester (Example, 0.70 mm). Calculation for the adjustment washer The thickness of the adjustment washer to be assembled is found by adding the valued from the reading obtained with the tester and a set value (0.40 mm). Example:

Reading obtained with the tester	0.70 mm
Set value	0.40 mm
Thickness of the adjustment washer	1.10 mm

The adjustment washer needed is found by using the following Table:

Thickness (mm)	Spares No.
0.65 0.70 0.75	02A 409 210 02A 409 210 A 02A 409 210 B
0.80 0.85 0.90	02A 409 210 C 02A 409 210 D 02A 409 210 E
0.95 1.00 1.05	02A 409 210 F 02A 409 210 G 02A 409 210 H
1.10 1.15 1.20	02A 409 210 J 02A 409 210 K 02A 409 210 L
1.25	02A 409 210 M

The diversity of the adjustment washers that exist allows the necessary thickness to be determined precisely for making a proper adjustment of the differential. –  Should the thickness of the adjustment washer needed be thicker than the thickness that appear in the Table, two adjustment washers may be fitted, the thickness for which when added together, correspond to the reading found. –  Once the adjustment washer needed has been determined, remove the tester. –  Extract the bolts that attach both casings and separate the gearbox casing. –  Separate the differential.

–  Extract the outer track for the tapered roller bearing from the gearbox casing with tool -U-40200/10- on the tool -U-40300/14-. –  Place the adjustment washer with the thickness calculated (in the example, 1.10 mm) in the housing for the outer track of the tapered roller bearing in the gearbox casing. –  Should two adjustment washers be needed, place the washer that is thicker first.

–  Assemble the outer track of the tapered roller bearing of the differential in the gearbox casing, with the adjustment washer, with tool -U-40200/10- and tool -U-40300/12-. –  Place the differential over the gearbox casing. –  Assemble the gearbox casing over the clutch casing and tighten the bolts for attaching them. Tightening torque: 25 Nm