Adjusting Differential

Adjusting differential, 02M/02Y, 5 & 6 Speed M/T, AWD
A new adjustment of differential is necessary if the following parts were replaced:
^ Transmission housing
^ Clutch housing
^ Differential housing
^ Tapered roller bearing for differential





Special tools, testers and auxiliary items required
^ Transmission support VW 353
^ End gauge VW 385/17
^ Dial gauge holder VW 387
^ Thrust plate VW 402
^ Punch VW 408 A
^ Thrust piece 3005





Special tools, testers and auxiliary items required
^ Tube 3259
^ Press tool 3345
^ Torque wrench V.A.G 1331
^ - 1 - Internal extractor Kukko 21/7
^ - 4 - Support Kukko 22/2

Work procedure





- Press outer race/tapered roller bearing with a 0.65 mm adjustment shim into clutch housing.

Note: Inner and outer race of tapered roller bearing are paired. Do not interchange.





- Press in outer race/tapered roller bearing without adjustment shim into transmission housing.
- Insert differential into clutch housing.
- Attach transmission housing and tighten 5 bolts to tightening torque.
- Press differential in direction of clutch housing and rotate eight times at the same time.
- Press differential in direction of 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 differential up and down, read off play on dial gauge and note (example: 0.70 mm).

Determining adjustment shim
The specified bearing pre-load is obtained by adding a constant pre-load figure of (0.30 mm) to reading obtained. Example:





- Determine shim thickness on the basis of the following table:





- Remove transmission housing.





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

A - Support Kukko 22/2
B - Internal puller 46 to 58 mm Kukko 21/7

- Insert adjustment shim of determined thickness, thickest shim first.





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