SEAT Workshop Service and Repair Manuals

Differential: adjustment

Special tools and workshop equipment required

t	Multi-purpose stand for the comparator -T20020-

t	Turning torque tester -U-40065-

t	Case for extractor tools for gearboxes -U-40100-

t	Case for repairing gearboxes -U-40200-

t	Replacement parts repair case -U-40300-

Adjust the differential when any of the following parts has been replaced: l  Gearbox casing l  Clutch casing l  Differential box l  Tapered roller bearing for the differential In order to avoid useless adjustment work, consult the Adjustments Chart → Chapter.

–  Assemble the outer track of the tapered roller bearing for the differential in the clutch casing with an S1 adjustment washer 1 mm thick. Use tools -U-40200/10- and -U-40200/13-.   Note! The tapered roller bearings and their corresponding outer tracks come in pairs. Do not mix them up or exchange them with other bearings.

–  Fit the outer track of the differential tapered roller bearings to the clutch casing without the S2 adjusting washer. Use tools -U-40200/10- and -U-40200/13-.   Note! The tapered roller bearings and their corresponding outer tracks come in pairs. Do not mix them up or exchange them with other bearings. –  Attach the differential to the gearbox casing. –  Mount the clutch casing onto the gearbox casing and screw in the securing bolts. t  Tightening torque: 25 Nm

–  Place the tool -T20020- with a comparator onto the gearbox casing. Place the end of the tool on the differential and fir the tool -U-40200/11- between them. –  Adjust the comparator 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 comparator (Example, 1.5 mm).   Note! During the measuring, do not turn the differential because the tapered roller bearings settle, thereby giving a false result for the measurement. Calculation for the S2 adjustment washer The thickness of the adjustment washer to be assembled is found by adding the valued from the reading obtained with the comparator and a set value. Example:

Reading obtained with the comparator	1,5 mm
Set value	0,3 mm
Thickness of the S2 adjustment washer	1,8 mm

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

Thickness (mm)	Replacement part 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 adjustment washer has been found, remove the comparator. –  Take out the bolts that secure both casings together and detach the clutch casing. –  Remove the differential.

–  Extract the outer track for the tapered roller bearing for the differential in the clutch casing using tool -U-40100/2-. –  Place the S2 adjustment washer with the thickness calculated (in this case 1.8 mm) in the housing for the outer track for the differential tapered roller bearing. –  If it is necessary to assemble two adjustment washers, put the thickest washer into place first.

–  Using tool -U-40200/10- and tool -U-40200/13-, attach the outer track of the tapered roller bearing of the differential in the clutch casing. –  Attach the differential to the gearbox casing. –  Mount the clutch casing onto the gearbox casing and screw in the securing bolts. t  Tightening torque: 25 Nm –  Check the friction torque. Checking the friction torque Before checking the friction torque, impregnate the tapered roller bearings with gear oil.

–  Set tool -U-40300/18- with the turning torque tester -U-40065- onto the differential housing. Friction torque: t  New bearings: 120…250 Ncm t  Used bearings: minimum 30 Ncm