SEAT Workshop Service and Repair Manuals

Adjusting differential

Special tools and workshop equipment required

t	Adjusting tool -VW 385/17-

t	Adjusting tool -VW 387-

t	Support equipment -VW 401-

t	Support equipment -VW 402-

t	Thrust piece -VW 408A-

t	Plunger -VW 412-

t	Crown wheel adjusting tool -VW 521-

t	Thrust piece -T10266-

t	Assembly tool -3291/2-

t	Assembly accessories -VW 472/1-

t	-1-Divider -KUKKO 21/8-

t	-4-Divider -KUKKO 22/2-

It is necessary to readjust the differential when t  Differential cage is renewed.

–  Press tapered roller bearing outer race, without shim, into clutch housing.

–  Press tapered roller bearing outer race with 0.65 mm thick shim into gearbox housing to stop. –  Place the differential on the clutch housing. –  Fit clutch housing and tighten 5 bolts to specified torque.

–  Secure the adjustment tool -VW 521/4- on the differential box (on gearbox housing side) using the gear wheel adjustment tool -VW 521/13-. –  Secure universal dial gauge bracket -VW 387- to clutch housing and set dial gauge to „0“ with 1 mm preload. –  Swing gearbox in assembly stand with clutch housing upwards.

–  Press differential in direction of clutch housing while turning it eight times. –  Move the differential box up and down using the adjustment tool -VW 521/4-, read off and note the play on the dial gauge. (Example: 0.70 mm.) Determine shim from table → Anchor. l  Perform measurement as shown in figure. Otherwise the measured value will be wrong. Determining thickness of shim. –  Remove gearbox housing.

–  Pull tapered roller bearing outer race out of clutch housing. A -  Puller -KUKKO 22/2- B -  Puller -KUKKO 21/8- –  First lay washer in clutch housing.   Note Observe installation position of washer. Shoulder on inner diameter faces seal. –  Then insert shim of determined thickness (in example, 0.95 mm). The following shims are used:

Bearing play	Shim
bearing clearance (mm)	Thickness (mm)
0,65 … 0,675 0,676 … 0,725 0,726 … 0,775	0,65 0,70 0,75
0,776 … 0,825 0,826 … 0,875 0,876 … 0,925	0,80 0,85 0,90
0,926 … 0,975 0,976 … 1,025 1,026 …1,075	0,95 1,00 1,05
1,076 …1,125 1,126 …1,175 1,176 …1,225	1,10 1,15 1,20
1,226 …1,275 1,276 …1,325 1,326 …1,375	1,25 1,30 1,35
1,376 …1,425	1,40

Note Allocate shims using → Electronic parts catalogue (ETKA). If the size of shim required is larger than those listed in the table, insert two shims totalling the correct figure.

The various thicknesses make it possible to achieve the exact shim thickness required. –  Press in outer race again and bolt gearbox housing tight.