Volkswagen Workshop Service and Repair Manuals

Adjusting differential

Special tools and workshop equipment required

t	Gearbox support -VW 353-

t	End dimension plate -VW 385/17-

t	Universal dial gauge bracket -VW 387-

t	Pressure plate -VW 402-

t	Press tool -VW 408 A-

t	Thrust plate -3005-

t	Tube -3259-

t	Tube -3345-

t	Torque wrench -V.A.G 1331-

t	-1-Internal puller -Kukko 21/7-

t	-4-Counter support -Kukko 22/2-

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 with shim (thickness 0.65 mm) into clutch housing. → Fig.   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 gearbox housing and tighten 5 bolts to specified torque → Item and → 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. A -  30 mm dial gauge extension –  Move differential up and down. Read and note play indicated on dial gauge. (Example: 0.70 mm) Determining thickness of shim. The specified bearing preload is obtained by adding a constant value for preload (0.30 mm) to the reading obtained. Example:

	Measured value	0.70 mm
+	Preload (constant)	0.30 mm
	Thickness of shim =	1.00 mm

–  Remove gearbox housing.

–  Pull tapered roller bearing outer race out of gearbox housing. A -  Counter support, e.g. -Kukko 22/2- B -  Internal puller, 46…58 mm, e.g. -Kukko 21/7- –  Determine thickness of shim from table. –  Determine part number of shim according to → Electronic parts catalogue (ETKA). –  Insert shims of determined thickness, thickest shim first. The following shims are available:

Shim thickness (mm)
0.65	0.85	1.05	1.25
0.70	0.90	1.10
0.75	0.95	1.15
0.80	1.00	1.20

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 specified torque → Item and → Item.