Differential, Adjusting

Differential, adjusting, 02M, 5 and 6 Spd. M/T

Special tools and equipment:

- VW 353 Transmission support
- VW 385/17 End measuring plate
- VW 387 Universal dial gauge bracket
- VW 402 Thrust plate
- VW 408 A Press tool
- 3005 Press disk

Special tools and equipment:

- 3259 Tube
- 3345 Tube
- V.A.G 1331 Torque wrench
1 - Kukko 21/7 Internal puller
4 - Kukko 22/2 Counter support

The differential must be adjusted, when
- Transmission housing
- Clutch housing
- Differential housing or the
- Differential tapered roller bearing have been replaced.
- Adjustment overview.
- Press tapered roller bearing outer race with shim (thickness 0.65 mm) into clutch housing.

Note: Inner and outer tapered roller bearing races are a pair. Do not interchange.





- Press tapered roller bearing outer race without shim into transmission housing.
- Install differential into clutch housing.
- Install transmission housing and tighten 5 bolts to specified torque.
- Press differential in direction of clutch housing and when doing this turn it eight times.
- Press differential in direction of transmission housing and when doing this turn it eight times.





- Mount dial gauge and zero with 1 mm preload.
A - Dial gauge extension 30 mm
- Move differential up and down and recall play indicated on dial gauge (Example: 0.70 mm).

Determining shim thickness
The specified bearing preload is obtained by adding a constant figure (0.30 mm) to reading obtained.

Example:





- Take off transmission housing.





- Pull tapered roller bearing outer race out of transmission housing.
A - Counter support, e.g. Kukko 22/2
B - Internal puller 46 to 58 mm, e.g. Kukko 21/7
- Insert shims of correct thickness, thickest shim first.
- The following shims are available:





If the size of the shim required is larger than that listed in the table, insert two shims totaling the correct figure.

By measuring the shims, varying tolerances make it possible to obtain the exact shim thickness required.





Press outer race in again and tighten transmission housing to specified torque.