Differential, Adjusting

Differential, Adjusting

A new differential adjustment is required when the following components have been replaced:

• Transmission housing

• Clutch housing

• Differential housing

• Differential tapered roller bearing

List of adjustments, refer to => [ Adjustment Overview ] Adjustment Overview.

Special tools, testers and auxiliary items required

• Transmission Support (VW 353)

• Magnetic Plate 50 mm Dia. (VW 385/17)

• Dial Gauge Holder (VW 387)

• Thrust Plate (VW 402)

• Punch (VW 408 A)

• Oil Pump Align Plate (3005)

• Tube (3259)

• Press Tool (3345)

• Torque Wrench (V.A.G 1331)

• Dial Gauge (VAS 6080)

• Kukko 21/7 internal puller

• Kukko 22/2 counter-support

• Dial gauge extension 30 mm

Procedure

- Press the outer ring for the tapered roller bearing with an adjustment shim into the clutch housing.

• The shoulder on the inner diameter of the (3005) points toward the outer ring.





- Press the outer ring for the tapered roller bearing without an adjustment shim into the transmission housing.





- Insert differential into clutch housing.

- Attach the transmission housing and tighten the 5 bolts to tightening specification - 11 - => [ Bolt ] Transmission Housing and Shift Mechanism Assembly Overview and - 12 - => [ Bolt ] Transmission Housing and Shift Mechanism Assembly Overview.

- Press differential in direction of clutch housing and rotate eight times at the same time.

- Press the differential in the direction of the transmission housing and rotate eight times at the same time.

- Install dial gauge and set to 0 with 1 mm pre-load.





A Dial gauge extension 30 mm

- Move the differential up and down and read the play on the dial gauge and note it (example: 0.70 mm).

Determining Shim Thickness

The specified bearing pre-load is obtained by adding a constant pre-load figure of (0.25 mm) to the reading obtained.

Example:






- Remove transmission housing.

- Pull outer race/tapered roller bearing out of transmission housing.





A Support, for example (Kukko 22/2)
B Internal puller 46 to 58 mm, for example (Kukko 21/7)

- Determine the adjustment shim thickness according to the table; part numbers. Refer to the electronic parts catalog ETKA.

- Insert shim of correct thickness.

The following shims are available:






Different shim thicknesses make it possible to select the required thickness precisely.

If the measured shim thickness is greater than the one listed in the table, two adjustment shims totaling the correct value can be installed. First the thicker adjustment shim must be inserted for this.

- Press in the outer ring again and fasten the transmission housing. Refer to => [ Transmission Housing and Shift Mechanism Assembly Overview ] Transmission Housing and Shift Mechanism Assembly Overview.