Differential Bearing, Manual Transaxle
Bearing plate, servicingSpecial tools, testers and auxiliary items
^ Internal puller 18.5-23.5mm (e.g. Kukko 21/3)
^ Counter support (e.g. Kukko 22/1)
^ Press tool VW408a
^ Guide pin 10-15
^ Thrust pad 30-504
^ Depth gauge
1. Bearing plate
^ If replacing, redetermine shim "S4"
2. Outer race for taper roller bearing for drive pinion.
^ Driving out
^ Pressing in
^ If replacing, redetermine shim "S4"
3. Shim S4
^ Adjustment overview
^ Redetermining
4. Cylinder roller bearing for input shaft
^ Pressing out see Fig. 5
^ Pressing In see Fig. 6
^ Measuring insertion depth see Fig. 7
5. Ball sleeve
^ For selector rods
^ Removing and installing see Fig. 1
^ Replace
6. Bolt, 35 Nm
^ For relay lever
7. Dowel pin (7 x 28)
^ Press in flush
8. Sliding gear for reverse gear
9. Synchro-ring for reverse gear
^ With locking pins
^ Checking for wear see Fig. 2
^ Installation position: flat on circumference of synchro-ring faces towards input shaft
10. Spring
^ Installation position: hook single angled end into recess on synchro-ring. Turn double angled end anti clockwise and insert into opening on bearing plate.
11. Shaft for reverse sliding gear
12. Retaining plate
^ Installation position: the chamfers of the holes for the locking pins of the synchro-ring towards bearing plate.
13. Spring clasp
14. Bolt, 25 Nm
^ Self locking
^ Replace
15. Relay lever for reverse gear
16. Follower for reverse gear
^ Pulling out ball sleeve see Fig. 3
^ Driving in ball sleeve see Fig. 4
17. Selector rod for 5th and 6th gear
^ Replace only complete with follower
Fig. 1 Removing and installing ball sleeves for selector rods
^ Insertion depth a = 2.5 mm
Fig. 2 Checking synchro-ring for wear
- Press synchro-ring onto cone of the gear.
- Measure gap "a" with a feeler gauge:
^ Dimension, new: 0.75 - 2.3 mm
^ Wear limit: 0.2 mm
Fig. 3 Pulling ball sleeve out of follower for reverse gear
A - Counter support, e.g. Kukko 22/1
B - Internal puller 18.5-23.5 mm, e.g. Kukko 21/3
Fig. 4 Driving ball sleeve flush into follower for reverse gear
Fig. 5 Pressing cylinder roller bearing for input shaft out of bearing plate
Fig. 6 Pressing cylinder roller bearing for input shaft into bearing plate
Insertion depth depends on serial number of transmission.
- Measuring insertion depth see Fig. 7.
Fig. 7 Measuring insertion depth of cylinder roller bearing for input shaft
a = 7 mm
Shim "S4," re-determining
Special tools, testers and auxiliary items required:
^ End measuring plate VW385/32
^ Clamping sleeve 3116
^ Hexagon bolt 3116/1
^ Depth gauge, accurate to 5/100 mm
^ Caliper gauge, accurate to 5/100 mm
^ Torque wrench
This adjustment is necessary when replacing following components:
^ Bearing plate
^ Hollow shaft
This adjustment re-creates the preload of the taper rollers for the drive pinion and hollow shaft.
1. Shim "S4"
2. Bearing plate
3. Transmission - housing
4. Hollow shaft
5. Drive - pinion/hollow shaft taper roller bearing
6. Drive pinion
a - Bearing plate housing depth
b - Dimension from drive pinion head to contact shoulder of taper roller bearing on hollow shaft
^ Taper roller bearings (drive pinion/hollow shaft) preloaded to 10 Nm.
S4 -Thickness of shim "S4"
Note: When replacing the drive pinion (final drive set), observe adjustment overview.
Determining shim when replacing bearing plate
- Use a depth gauge which is accurate to within at least 5/100 mm.
- Measure difference of depth "a" on old and new bearing plates
Example:
- If the new bearing plate is deeper, install a thicker "S4" shim.
- If the old bearing plate is deeper, install a thinner "S4" shim.
Example:
Available shims, table.
Determining shim when replacing hollow shaft
- Use a caliper gauge, which is accurate to within at least 5/100 mm.
- Tighten tensioning sleeve to exactly 10 Nm.
A - Vice clamps
- Fit end measuring plate VW 385/32 onto drive pinion head and measure dimension "d".
^ Upper measuring point is the contact shoulder for inner race of small taper roller bearing
Example: 248.50 mm
- Install new hollow shaft and measure dimension "d" again.
Example: 248.70 mm
- Determine difference:
- Install a correspondingly thinner shim "S4" if dimension "d" of new hollow shaft is greater.
- Install a correspondingly thicker shim "S4" if dimension "d" of new hollow shaft is less.
- Determine shim(s) from table: part numbers
Available shims for "S4"
1. Using the shim tolerance variations it is possible to find the exact shim thickness required, insert two shims if necessary.