SEAT Workshop Service and Repair Manuals

Differential: adjustment

Special tools and workshop equipment required

t	Universal dial gauge bracket -T20020-

t	Turn torqe checking tool -U-40065-

t	Gearbox extractor set -U-40100-

t	Gearbox repair set -U-40200-

t	Gearbox repair set -U-40300-

Adjust the differential when one of the following elements have been replaced: l  Gearbox casing l  Clutch housing l  Differential casing l  Input shaft roller bearings Refer to Adjustment chart

–  Fit the outer track of the differential roller bearings into the gearbox casing, with an S1 1mm thick shim.   Note! The roller bearings and their corresponding outer tracks are matched pairs. Do not mix with other bearings.

–  Fit the outer track of the differential conical roller bearings into the clutch housing, without the S2 shim. –  Place the differential on the gearbox housing. –  Fit the clutch housing onto the gearbox casing 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-40200/11-. –  Adjust the dial gauge to “0” with a pre-tension of 1 mm. –  Move the differerential alternately in the direction of the arrows. –  Take note of the meaurement obtained (e.g. 1.5 mm).   Note! When measuring do not turn the differential, because the roller bearings may setle an the reading would be erroneous. S2 shim calcuation table The pre-tension of the bearing is obtained by adding a onstant presure value (0.3 mm) to the obtained measurement value of S2 (in the example: 1.80 mm). Example:

Average value	1.50 mm
+ Pressure (const. value)	0,30 mm
S2 shim thickness	1.80 mm

The shim needed will be determined by the following table:

Thickness (mm)	Spare no.
1.00 1.40 1.45	084 409 383 AE 084 409 383 AF 084 409 383 AG
1.50 1.55 1.60	084 409 383 AH 084 409 383 AJ 084 409 383 AK
1.65 1.70 1.75	084 409 383 AL 084 409 383 AM 084 409 383 AN
1.80 1.85 1.90	084 409 383 AP 084 409 383 AQ 084 409 383 AR
1.95 2.00 2.05	084 409 383 AS 084 409 383 AT 084 409 383 BA
2.10 2.15 2.20	084 409 383 BB 084 409 383 BC 084 409 383 BD
2.25 2.30 2.35	084 409 383 BE 084 409 383 BF 084 409 383 BG
2.40	084 409 383 BH

–  Once the necessary S2 shim has been determined, remove the dial gauge. –  Remove the bolts that secure both casings and separate the clutch housing. –  Separate the diferential.

–  Remove the differential outer roller bearing track from the clutch housing with tool -U-40100/2-. –  Fit the S2 shim of the correct thickness (in this case 1.8 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 clutch housing, with tool -U-40200/10- and tool -U-40200/13-. –  Place the differential on the gearbox housing. –  Fit the clutch housing onto the gearbox casing and tighten the securing bolts to 25 Nm. –  Check the friction torque. Checking the friction torque Before checking the friction torque, coat the roller bearings with gearbox oil.

–  Fit tool -U-40300/18-, with the turn torque checking tool -U-40065-, on the differential housing. Das erhaltene Reibmoment muß folgende Werte haben: t  New bearings: 120…250 Ncm. t  Used bearings: 30 Ncm.