Differential Adjusting

5 Speed Manual 02J

Differential, Adjusting





Special Tools
- VW 387 Universal dial gauge bracket
- VW 385/17 End measuring plate
- 30-205 Thrust plate
- V\N 407 Press tool
- Dial indicator (not illustrated)

The differential must be adjusted when any of the following components have been replaced:
- Transmission housing
- Clutch housing
- Differential housing
- Differential tapered roller bearing

Adjustment overview. Refer to Adjustments.
- Press tapered roller bearing outer race into clutch housing using thrust plate 30-205.

Note:
- Tapered roller bearing inner and outer races are paired. Do not interchange!

- Press tapered roller bearing outer race without shim into the transmission housing using thrust piece 30-205.
- Mount differential into clutch housing
- Install transmission housing and tighten 5 bolts to 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 obtained.





- Remove transmission housing and pull tapered roller bearing outer race out from transmission housing.
- 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 totaling the correct figure.
Varying tolerances make it possible to obtain the exact shim thickness required by measuring the shims.
- Drive in outer race again and tighten transmission housing.