Differential, Adjusting

Differential, adjusting, 02M/02Y, 5 & 6 Speed M/T, AWD





Special tools and equipment
^ VW 353 transmission mount
^ VW 385/17 magnetic plate
^ VW 387 dial indicator holder
^ VW 402 thrust plate
^ VW 408 A punch
^ 3005 thrust pad





Special tools and equipment
^ 3259 tube
^ 3345 press tool
^ VAG1331 torque wrench
^ 1 - Kukko 21/7 puller
^ 4 - Kukko 22/2 support

New adjustment of differential is necessary when:
^ Transmission housing
^ Clutch housing
^ Differential housing
or the
^ Tapered roller bearing of differential are replaced.
- Press tapered roller bearing outer race with shim (thickness 0.65 mm) into clutch housing.

Note: Tapered roller bearing inner and outer races are paired. Do not interchange.





- Press tapered roller bearing outer race without adjustment shim into transmission housing.
- Insert differential gear into clutch housing.
- Install transmission housing and tighten 5 bolts with tightening torque.
- Press differential in direction of clutch housing and rotate 8 times at the same time.
- Press differential in direction of transmission housing and rotate 8 times at the same time.





- Install dial indicator and set to 0 with 1 mm preload.

A - Dial indicator extension 30 mm

- Move differential up and down, read play on dial indicator and note (i.e.: 0.70 mm)

Select shims
The specified bearing preload is reached if a constant preload value of (0.30 mm) is added to the determined measured value.

Example:





- Remove transmission housing.





- Pull tapered roller bearing outer race from transmission housing.

A - Support, i.e. Kukko 22/2
B - Puller 46...58 mm, i.e. Kukko 21/7

- Insert determined size shim, beginning with the thickest shim.

The following shims are available:





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