Differential: Adjustments

Differential, Adjusting

=> [ Shim S, Selecting ]

Special tools, testers and auxiliary items required

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

• Dial Gauge Holder (VW 387)

• Thrust Plate (VW 401)

• Thrust Plate (VW 402)

• Punch (VW 408 A)

• Thrust Disc (VW 412)

• Thrust Pad (VW 510)

• Sleeve (30-14)

• Press Tube (2040)

• Tube (3259)

• Press Tool (3345)

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• Thrust Pad (30-205)

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

• Transmission housing

• Clutch housing

• Differential housing

or the

• Differential tapered roller bearing

Shim S1 for the Outer Race/Tapered Roller Bearing is Deleted as of Production date 04 December 2006





The outer race/tapered roller bearing seat has been adapted.

Perform the following work:

- Measure the bearing seat depth in the transmission housing for the outer race/tapered roller bearing.





Continuation for All

- Install the outer race/tapered roller bearing into the transmission housing, if necessary, with a 1 mm shim S1.





• Bearing inner and outer races for the tapered roller bearing are paired. Do not interchange them.

- Install the tapered roller bearing inner race (opposite drive gear side) without adjustment shim into the clutch housing.





- Insert the differential into the transmission housing.

- Position clutch housing and tighten the 5 bolts to specification. Refer to => [ Clutch Housing ] Transmission Component Overviews.

- Install the dial gauge and set it to "0" with a 1 mm preload.





A 30 mm dial gauge extension

- Move differential up and down, read off play on dial gauge and note. (example: 1.50 mm).

Shim S2, Selecting

The specified bearing preload is obtained by adding a constant preload figure of 0.35 mm to the reading obtained for S2.

Example





- Remove the clutch housing and press out the tapered roller bearing inner race - A -.





B Internal puller 46 to 58 mm, for example, (21/7)

- For the correct shim(s), refer to the Parts Catalog.

Tolerance variations make it possible to find the exact shim thickness required.

If the measured washer thickness is greater than that listed in Parts Catalog, 2 washers that correspond to the measured value can be installed.

- Insert the shim S2 (1.85 mm in example) and press tapered roller bearing inner race into clutch housing again.

- Position the clutch housing and tighten the bolts to specification. Refer to => [ Clutch Housing ] Transmission Component Overviews.