Differential, Adjusting

Differential, Adjusting

Special tools, testers and auxiliary items required

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

• Dial Gauge Holder (VW 387)

• Punch (VW 407)

• Thrust Pad (30-205)

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

• Kukko Extractor 46-58 mm (21/7)

• Kukko Support (22/2)

• Dial Gauge

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

Adjustment overview. Refer to => [ Adjustment Overview ] Adjustment Overview.

- Press the tapered roller bearing outer race into the transmission housing without a shim, using the thrust pad (30-205). Refer to => [ Installing the Outer Race/Tapered Roller Bearing into the Transmission Housing ] Service and Repair.

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

- Press the tapered roller bearing outer race into the clutch housing, using the thrust pad (30-205). Refer to => [ Installing the Outer Race/Tapered Roller Bearing into the Clutch Housing ] Service and Repair.

- Insert the differential into the clutch housing.

- Mount the transmission housing and tighten the five bolts to 25 Nm.

- Attach the dial gauge holder (VW 387) and set the dial gauge to "0" with a 1 mm preload.






- Move the differential up and down, read off the play on the dial gauge and note. Example: to 0.70 mm).

Shim, Selecting

The specified bearing preload is obtained by adding a constant preload figure of 0.25 mm to the reading obtained.

Example:






Example:






Adjustment Shim Table






• For the correct shims, refer to the Parts Catalog.

- Remove the transmission housing and remove the tapered roller bearing outer race from the transmission housing.






A Counter support, for example, Kukko support (22/2)
B Internal puller 46 to 58 mm, for example, Kukko extractor 46-58 mm (21/7)

- Insert the shim with the correct thickness.

If the measured shim thickness is larger than those listed in the table, then install two adjusting shims that add up to the necessary thickness. Insert the thickest adjusting shim first.

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

- Install the tapered roller bearing inner race again, refer to => [ Installing the Outer Race/Tapered Roller Bearing into the Transmission Housing ] Service and Repair and install the transmission housing.