Volkswagen Workshop Service and Repair Manuals

Adjusting differential

Special tools and workshop equipment required

t	End dimension plate -VW 385/17-

t	Universal dial gauge bracket -VW 387-

t	Pressure plate -VW 402-

t	Pressure plate -VW 401-

t	Press tool -VW 408-

t	Press tool -VW 412-

t	Thrust plate -30-205-

t	Tube -30-14-

t	Tube -2040-

t	Tube -3259-

t	Torque wrench -V.A.G 1331-

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

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 Requirement: l  Sealing surfaces of clutch and gearbox housings must be free of sealant.

–  Pressing tapered roller bearing outer race (gear wheel slide) into gearbox housing.   Note Inner and outer tapered roller bearing races are paired. Do not interchange!

–  Press tapered roller bearing outer race (opposite gear wheel) with no shim into gearbox housing. –  Insert differential in gearbox housing. –  Fit clutch housing and tighten 5 bolts to specified torque.

–  Attach dial gauge and set to „0“ with 1 mm preload. A -  30 mm dial gauge extension –  Set dial gauge to „0“ with 1 mm preload for bearing. –  Move differential up and down. Read and note play indicated on dial gauge. (Example: 1.50 mm) Determining thickness of shim The specified bearing preload is obtained by adding a constant value for preload (0.35 mm) to the reading obtained. Example:

Measured value	1.50 mm
+ Preload (constant)	0.35 mm
Thickness of shim =	1.85 mm

–  Remove clutch housing and press out tapered roller bearing outer race -A-. B -  Internal puller, 46…58 mm, e.g. -Kukko 21/7- –  Allocate shim(s) using → Electronic parts catalogue „ETKA“. The various thicknesses make it possible to achieve the exact shim thickness required. If the size of shim required is larger than those listed in the → Electronic parts catalogue „ETKA“, insert two shims totalling the correct figure. –  Insert correct shim (in example 1.85 mm) and press tapered roller bearing outer race into clutch housing again. –  Fit clutch housing and tighten bolts to specified torque setting.