volkswagen Workshop Repair Guides

Volkswagen Workshop Service and Repair Manuals

ABOUT US
6-speed manual gearbox 02Q > < Dismantling and assembling differential

Golf Mk6

Adjusting differential
   
Adjusting differential
Special tools and workshop equipment required
t  Universal dial gauge bracket -VW 387-
t  End dimension plate -VW 385/17-
t  Press tool -VW 407-
t  Thrust plate -30 - 205-
t  Torque wrench -V.A.G 1331-
t  Internal puller -1 - Kukko 21/7-
t  Counter support -4 - Kukko 22/2-
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.
–  Press outer race of tapered roller bearing without shim into gearbox housing using thrust piece -30 - 205- → Fig.
  Note
Inner and outer tapered roller bearing races are paired. Do not interchange!
–  Press outer race of tapered roller bearing into clutch housing using thrust plate -30 - 205- → Fig..
–  Fit differential into clutch housing.
–  Set gearbox housing in place and tighten 5 bolts to 25 Nm.
   
–  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)
Determining thickness of shim
Example:
  V39-1278
Bearing play, measured valueThickness of shim according to table
0.70 mm0.95 mm

Table of shims
   
Bearing playShim
bearing clearance
(mm)		Thickness
(mm)
0.303 … 0.449
0.450 … 0.499
0.500 … 0.549		0.650
0.700
0.750
0.550 … 0.599
0.600 … 0.649
0.650 … 0.699		0.800
0.850
0.900
0.700 … 0.749
0.750 … 0.799
0.800 … 0.849		0.950
1.000
1.050
0.850 … 0.899
0.900 … 0.949
0.950 … 0.999		1.100
1.150
1.200
1.000 … 1.049
1.050 … 1.099
1.100 … 1.149		1.250
1.300
1.350
1.150 … 1.1991.400

  Note
Allocate shims using → Electronic Parts Catalogue (ETKA).
–  Remove gearbox housing and pull tapered roller bearing outer race from gearbox housing.
   
Pulling outer race for tapered roller bearing out of gearbox housing
A - Counter support, e.g. -Kukko 22/2-
B - Internal puller 46 …. 58 mm, e.g. -Kukko 21/7-.
–  Insert shims of determined thickness, thickest shim first.
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 in tapered roller bearing outer race together with the correct shim (in example 0.95 mm) again → Fig. and bolt gearbox housing tight.
  N39-0026

6-speed manual gearbox 02Q > < Dismantling and assembling differential