Differential, Adjusting

Differential, Adjusting

Special tools, testers and auxiliary items required

• Magnetic Plate 50 mm Dia. (385/17)

• Dial Gauge Holder (VW 387)

• Thrust Plate (VW 401)

• Thrust Plate (VW 402)

• Punch (VW 408 A)

• Thrust Disc (VW 412)

• Crown Wheel Adjustment Device (VW 521)

• Thrust Piece (T10266)

• Assembly Device (3291)

• Thrust Pad (VW 472/1)

• Kukko Extractor 56-70 mm (21/8)

• Kukko Support (22/2)

The differential must be adjusted, when the

• Differential housing

is replaced.

- Installing the outer race/tapered roller bearing without a adjustment shim into the clutch housing.






- Install the tapered roller bearing outer race with a 0.65 mm adjustment shim into the transmission housing.






- Insert the differential into the clutch housing.

- Position the transmission housing and tighten the 5 bolts to specification.

- Install the locking sleeve (VW 521/4) on the differential housing (transmission housing side) with the shell (VW 521/13).






- Install the dial gauge holder (VW 387) on the clutch housing and set the gauge with 1 mm pretension to "0".

- Swivel the transmission in the assembly stand with the clutch housing upward.

- Push the differential toward the clutch housing and rotate eight times at the same time.






- Move the differential up and down, and read the play on the dial gauge and note. (example: 0.70 mm).

Determine the shim according to the table.

• The measurement must be performed as shown in the illustration otherwise the measured value will be wrong.

Shim, Determining

- Remove the transmission housing.

- Remove the tapered roller bearing outer race from the clutch housing.






A Support, for example, (22/2)
B Extractor 56-70 mm, for example (21/8)

- First place the washer into the clutch housing.

• Note the installed position of the washer, the shoulder on the inner diameter points toward the seal.

- Then, place the shim of the determined thickness (in the example: 0.95 mm).

The following adjusting shims are available:






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

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

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






- Install the outer race again and tighten the transmission housing.