volkswagen Workshop Repair Guides

Volkswagen Workshop Service and Repair Manuals

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Removing and installing rear final drive > < Checking gear oil in rear final drive and topping up

Golf Mk4

Adjusting differential
   
Adjusting differential
Special tools and workshop equipment required
t  End dimension plate -VW 385/17-
t  Universal dial gauge bracket -VW 387-
t  Thrust piece -VW 473-
t  Thrust plate -30 - 205-
t  Torque wrench -V.A.G 1331-
t  Dial gauge

It is necessary to readjust the differential when
t  Gearbox housing
t  Clutch housing
t  Differential cage
or the
t  Tapered roller bearing of differential
have been renewed.
Adjustment overview → Chapter.
–  Press tapered roller bearing outer race without shim into the clutch housing using thrust piece -30 - 205- → Fig..
  Note
Inner and outer tapered roller bearing races are paired. Do not interchange.
–  Press tapered roller bearing outer race without shim into the gearbox housing using thrust piece -30 - 205- → Fig..
–  Fit differential into clutch housing.
–  Fit clutch housing and tighten 5 bolts to specified torque → Item.
–  Press differential in direction of clutch housing while turning it eight times.
–  Press differential in direction of gearbox housing while turning it eight times.
   
–  Attach dial gauge and set to “0” with 1 mm preload.
–  Move differential up and down. Read and note play indicated on dial gauge. (Example: 0.70 mm)
  Note
When performing measurement, do not turn differential or the bearings will settle and the result of the measurement will be falsified.
Determining thickness of shim.
The specified bearing preload is obtained by adding a constant value for preload (0.40 mm) to the reading obtained.
Example:
  V39-1278
Measured value0.70 mm
+ Preload (constant)0.40 mm
Thickness of shim =1.10 mm

–  Remove gearbox housing and pull out tapered roller bearing outer race out of gearbox housing → Fig. or press out with thrust piece -VW 473-.
–  Insert shims of determined thickness, thickest shim first.
The following shims are available:
   
Thickness (mm)Part number
0,65
0,70
0,75		02A 409 210
02A 409 210 A
02A 409 210 B
0,80
0,85
0,90		02A 409 210 C
02A 409 210 D
02A 409 210 E
0,95
1,00
1,05		02A 409 210 F
02A 409 210 G
02A 409 210 H
1,10
1,15
1,20		02A 409 210 J
02A 409 210 K
02A 409 210 L
1,2502A 409 210 M

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 outer race in again and tighten gearbox housing to torque setting → Item.
   

Removing and installing rear final drive > < Checking gear oil in rear final drive and topping up