Differential: Adjustments

5 Speed Manual 02J

Differential, adjusting

Special tools






- VW 387 Dial gauge holder
- VW 385/17 End measuring plate
- 30-205 Thrust pad
- VW 407 Punch

The differential must be adjusted when

- Transmission housing
- Clutch housing
- Differential housing
or the
- Differential tapered roller bearing have been replaced.

- Press tapered roller bearing outer race into clutch housing using thrust pad 30-205.

Note:
The tapered roller bearing inner and outer races are paired. Do not interchange!
- Press tapered roller bearing outer race without shim into transmission housing using thrust piece 30-205.
- Mount differential into clutch housing
- Install transmission housing.
Tightening torque: 25 Nm (18 ft. lbs.)





- Mount dial indicator and zero with 1.0 mm preload.
- Move differential up and down and record play shown on dial indicator (Example: 0.70 mm).

Determining shim thickness

The specified bearing preload is obtained by adding a constant figure (0 - 40 mm) to the reading.





- Remove transmission housing and pull tapered roller bearing outer race out.
- Insert shims of correct thickness, thickest shim first.

The following shims are available:





If the size of shim required is larger than those listed in the table, insert two shims totalling the correct figure.
Verifying shim tolerances make it possible to obtain the exact thickness required.
- Drive-in outer race again and install transmission housing.