Volkswagen Workshop Service and Repair Manuals

Adjusting differential

Special tools and workshop equipment required

t	Support plate -VW 309-

t	Gearbox support -VW 353-

t	Drift -VW 295-

t	Thrust piece -VW 554-

t	Thrust pad -VW 510-

t	Universal dial gauge bracket -VW 387-

t  Measuring plate -VW 385/17- t  Dial gauge It is necessary to readjust the differential when the following components are renewed: t  Gearbox housing t  Clutch housing t  Differential cage or the t  Tapered roller bearing of differential Adjustment overview → Chapter.

–  Drive in tapered roller bearing outer race with shim S2 (always 1 mm thick) into clutch housing.   Note Inner and outer tapered roller bearing races are paired. Do not interchange!

–  Press tapered roller bearing outer race without shim into gearbox housing. –  Fit differential into clutch housing. –  Fit clutch housing and tighten 5 bolts to specified torque.

–  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: 0.90 mm) Determining shim S1 The specified bearing preload is obtained for S1 by adding a constant figure for pressure (0.40 mm) to the measured value (example: 0.90 mm). Example:

Measured value	0.90 mm
+ Preload (constant)	0.40 mm
Thickness of shim S1 =	1.30 mm

–  Remove gearbox housing and pull tapered roller bearing outer race out from gearbox housing. –  Insert shim S1 of determined thickness, thickest shim first. The following shims are available:

Thickness (mm)	Part number
0.65 0.70	02K 409 210 02K 409 210 A
0.75 0.80 0.85	02K 409 210 B 02K 409 210 C 02K 409 210 D
0.90 0.95 1.00	02K 409 210 E 02K 409 210 F 02K 409 210 G
1.05 1.10 1.15	02K 409 210 H 02K 409 210 J 02K 409 210 K
1.20 1.25	02K 409 210 L 02K 409 210 M

Various tolerances make it possible to obtain the exact shim thickness required. If the size of shim required is larger than those listed in the table, insert two shims totalling the correct figure. –  Drive in outer race again, fit gearbox housing with gasket and tighten.