SEAT Workshop Service and Repair Manuals

Differential: adjusting

Special tools and workshop equipment required

t	Universal dial gauge bracket -T20020-

t	Gearbox extractor set -U-40100-

t	Gear box repair set -U-40200A-

Adjust the differential when one of the following elements has been replaced: l  Gearbox casing l  Clutch housing l  Differential casing l  Differential roller bearings Refer to Adjustment chart → Chapter.

–  Fit the outer track of the differential roller bearings into the gearbox casing, with an S1 1mm thick shim. Use tools -U-40200A/10- and -U-40200A/14- einsetzen.   Note! t  The roller bearings and their corresponding outer tracks are matched pairs. Do not mix with other bearings. t  Replace the two roller bearings together.

–  Fit the outer track of the differential conical roller bearings into the clutch housing, without the S1 shim. Use tools -U-40200A/10- and -U-40200A/14-.   Note! The roller bearings and their corresponding outer tracks are matched pairs. Do not mix with other bearings. –  Place the differential on the clutch housing. –  Fit the gearbox casing onto the clutch housing and tighten the securing bolts to 25 Nm.

–  Fit tool -T20020- on the gearbox casing with a dial gauge. Locate the end of the gauge on the differential, interplacing tool -U-40200A/11-. –  Adjust the dial gauge to “0” with a pre-tension of 1 mm. –  Move the differential alternately in the direction of the arrows. –  Take note of the measurement obtained (e.g. 0.9 mm)   Note! When measuring do not turn the differential, because the roller bearings may settle and the reading would be erroneous. S1 shim calcuation table The pre-tension of the bearing is obtained by adding a constant pressure value (0.4 mm) to the obtained measurement value of S1 (in the example: 0.90 mm). Example:

Average value	0.90 mm
+ Pressure (const. value)	0.40 mm
S1 shim thickness needed	1.30 mm

The shim needed will be determined by the following table:

Thickness (mm)	Spare no.
0.15 0.30 0.60 0.70 0.75 0.80 0.85 0.90 0.95 1.00 1.05 1.10 1.15 1.20 1.25	020 409 231 020 409 231 A 020 409 231 D 02K 409 210 A 02K 409 210 B 02K 409 210 C 02K 409 210 D 02K 409 210 E 02K 409 210 F 02K 409 210 G 02K 409 210 H 02K 409 210 J 02K 409 210 K 02K 409 210 L 02K 409 210 M

The existence of different tolerances allows the exact calibration of the thickness of the shim needed. If the thickness of the shim needed is greater than the shims in the table, two shims that come to the required thickness can be fitted. –  Once the necessary S1shim has been determined, remove the dial gauge. –  Remove the bolts that secure both casings and separate the gearbox casing. –  Separate the differential.

–  Remove the differential outer roller bearing track from the earbox casing with tool -U-40100/2-. –  Fit the S1 shim of the correct thickness (in this case 1.3 mm) into the housing in the outer track of the differential roller bearing, –  If it is necessary to fit two shims, place the thickest one first.

–  Fit the differential outer roller bearing track to the gearbox casing, with tool U-40200A/10 and tool -U-40200A/10-. –  Place the differential on the clutch housing. –  Fit the gearbox casing onto the clutch housing and tighten the securing bolts to 25 Nm.