Differential, Adjusting

Differential, adjusting, 02J, 5 Spd. M/T

Special tools and equipment:

^ VW 387 Universal dial gauge bracket
^ VW 385/17 End measuring plate
^ 30-205 Thrust plate
^ VW 407 Press tool
^ Dial gauge

The differential must be adjusted, when
- Transmission housing
- Clutch housing
- Differential housing
or the
- Differential tapered roller bearing
have been replaced.

- Press tapered roller bearing outer race into clutch housing using thrust plate 30-205.

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

- Press tapered roller bearing outer race without shim into transmission housing using thrust piece 30-205.
- Install differential into clutch housing
- Fit transmission housing and tighten 5 bolts to 25 Nm.





- Mount dial gauge and "0" with 1 mm preload.
- Move differential up and down and recall play indicated on dial gauge (Example: 0.70 mm)

Determining shim thickness
The specified bearing preload is obtained by adding a constant figure (0.40 mm) to the reading obtained.
Example:





- Remove transmission housing and pull tapered roller bearing outer race out from transmission housing.
- Insert shims of correct thickness, thickest shim first.
The following shims are available:





If the size of shim required is larger than that listed in the table, insert two shims totaling the correct figure.

Varying tolerances make it possible by measuring the shims to obtain the exact shim thickness required.
- Drive in outer race again and tighten transmission housing.