Skoda Workshop Service and Repair Manuals

Adjusting the differential gear Special tools and workshop equipment required t  Gauge block plate -MP3-405/17 (VW 385/17)- t  Pressure plate -MP3-406 (VW 401)- t  Pressure plate -MP3-407 (VW 402)- t  Thrust piece -MP3-408 (VW 412- t  Pressure washer -MP3-413 (VW 510)- t  Universal dial gauge holder -MP3-447 (VW 387)- t  Thrust plate -MP3-464 (30-205)- t  Pressure pipe -MP6-408 (30-14)- t  Pipe -MP6-419 (3259)- t  Pipe -T30019 (3345)- t  Pipe section -T30041 (2040)- t  Interior extractor 46...58 mm, e.g. -Kukko 21/7- The differential gear must be re-set when the following components are replaced: t  Gearbox housing t  Clutch housing t  Differential housing or the t  differential gear tapered-roller bearing

Up to gearbox manufacturing date 05 05 2 –  Press the outer ring/tapered-roller bearing (pinion side) with adjusting washer S1 (always 1mm thick) into the gearbox housing.   Note The inner and outer rings of the tapered-roller bearing are paired. Do not interchange!

As of gearbox manufacturing date 06 05 2 –  Press the outer ring/tapered-roller bearing (pinion side), if necessary with adjusting washer S1 (always 1 mm thick)-, → Fig. into the gearbox housing with the pressure plate -MP3-464 (30-205) -. –  Check if on gearbox housings made out of aluminium (distinguishing feature = “AL”-arrow-), an adjusting washer S1 must be placed under the outer ring/tapered-roller bearing → Fig..   Note On gearboxes made out of aluminium as of manufacturing date 12.06 the adjusting washer S1 for outer ring/tapered-roller bearing is not fitted.

On gearboxes made out of aluminium as of manufacturing date 12.06 the adjusting washer S1 for outer ring/tapered-roller bearing is not fitted.

The bearing pedestal for outer ring/tapered-roller bearing is adapted –  Measure the depth of the bearing pedestal for the outer ring/tapered-roller bearing in the gearbox housing

Dimension “a”	Adjusting washer S1
15.2 mm	no
16.2 mm	yes

Continued for all gearboxes

–  Press the outer ring/tapered-roller bearing (opposite pinion side) without adjusting washer into the clutch housing. –  Insert the differential gear in the gearbox housing. –  Position the clutch housing and tighten 5 screws to the given tightening torque → Chapter.

–  Set up the measuring device and dial gauge (3 mm measuring range), dial gauge extension -A- approx. 30 mm). –  Set the dial gauge to 0 with 1 mm bias. –  Move the differential gear up and down, read off and write down the clearance on the dial gauge. (Example: 1,50 mm).   Note Do not turn the differential while measuring as otherwise the bearings will settle and the measuring result will be inaccurate. Determining adjusting washer S 2 The required bearing preload is reached by adding to the value measured for S 2 (for example: 1.50 mm) a constant value for pressure (0.25 mm for aluminium housings and 0.35 mm for magnesium housings). Example:    For housing in magnesium version:

measured value		1.50 mm
+ pressure (const. value)		0.35 mm
Thickness of the adjusting washer S2	=	1.85 mm

For housing in aluminium version:

measured value		1.50 mm
+ pressure (const. value)		0.25 mm
Thickness of the adjusting washer S2	=	1.75 mm

–  Remove the clutch housing and press out the outer ring/tapered-roller bearing -A-.    -B-Interior extractor 46 ... 58 mm, e.g. -Kukko 21/7- –  Position pipe -2040 (T30041)- directly on the feet of the interior extractor-B- and press out the outer ring/tapered-roller bearing -A-.   Note Assign the adjusting washer (s) via the → Electronic Catalogue of Original Parts. Available adjusting washers S2

Adjusting washer thickness (mm)
0,65	0,90	1,15
0,70	0,95	1,20
0,75	1,00	1,25
0,80	1,05
0,85	1,10

Different tolerances allow to measure the required thickness for each washer very precisely. If the measured washer thickness is greater than the one listed in the table, 2 washers corresponding to the measured value may be fitted. –  Insert adjusting washer S2 with the required thickness (in this example 1.75 or 1.85 mm) and press the outer ring/tapered-roller bearing back into the clutch housing. –  Position the clutch housing and tighten the screws to the given tightening torque → Chapter.