Volkswagen Workshop Service and Repair Manuals

Special tools and workshop equipment required

• ◆ VW 387 Universal dial gauge bracket
• ◆ VW 385/17 End measuring plate
• ◆ 30-205 Thrust plate
• ◆ VW 407 Press tool
• ◆ Dial gauge

Special tools and workshop equipment required

• ◆ V.A.G 1331 Torque wrench

• ◆ 1 - Kukko 21/7 Internal puller
• ◆ 4 - Kukko 22/2 Counter support

The differential must be adjusted, when

• ◆ Gearbox housing
• ◆ Clutch housing
• ◆ Differential housing

or the

• ◆ Differential taper roller bearing

have been renewed.

Adjustment overview .

• ‒ Press taper roller bearing outer race into clutch housing using thrust plate 30-205 => Page 39-14 .

Note:

Taper roller bearing inner and outer races are paired. Do not interchange!

• ‒ Pressing taper roller bearing outer race without shim into the gearbox housing using thrust piece 30-205 => Page 39-16 .
• ‒ Fit differential into clutch housing
• ‒ Fit gearbox housing and tighten 5 bolts to 25 Nm.

• ‒ → Mount dial gauge and "0" with 1 mm preload.
• ‒ Move differential up and down and recall play indicated on dial gauge
  (Example: 0.70 mm)

Determining shim thickness

The specified bearing preload is obtained by adding a constant figure (0.40 mm) to the reading obtained.

Example:

• ‒ Remove gearbox housing and pull taper roller bearing outer race out from gearbox housing => Page 39-16 .
• ‒ Insert shims of correct thickness, thickest shim first.

The following shims are available:

If the size of shim required is larger than that listed in the table, insert two shims totalling the correct figure.

Varying tolerances make it possible by measuring the shims to obtain the exact shim thickness required.

• ‒ Knock-in outer race again and tighten gearbox housing.