Adjusting the Differential

Adjusting the Differential

Special tools, testers and auxiliary items required

• Magnetic Plate (VW 385/17)

• Dial Gauge Holder (VW 387)

• Pressure Plate (VW 402)

• Punch (VW 408 A)

• Thrust Piece (3005)

• Tube (3259)

• Tube for Wheel Bearing (3345)

• - 1 - Internal Puller 46 to 58 mm (Kukko 21/7)

• - 4 - Counter-Support (Kukko 22/2)

It is necessary to readjust the differential when the following components are replaced:

• Transmission housing

• Clutch housing

• Differential housing

• Differential tapered roller bearing

List of adjustments. Refer to => [ Adjustment Overview ] Adjustment Overview.

Adjusting






- Press the outer race of tapered roller bearing with shim (0.65 mm thick) into the clutch housing.

• Shim installation position: the shoulder on inner diameter points toward sealing ring

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

- Press outer race of tapered roller bearing into transmission housing without shim.






- Insert differential into clutch housing.

- Set transmission housing in place and tighten 5 bolts to tightening specification => [ (Item 11) Bolt ] Transmission Housing and Shift Mechanism Overview.

- 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 gauge and set to "0" with 1 mm pre-load.






A Dial gauge extension 30 mm

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

Determining shim thickness:

The specified bearing pre-load is obtained by adding a constant pre-load figure of (0.25 mm) to the reading obtained.






- Determine the shim thickness according to the table; for the part number, refer to the Parts Catalog.

The following shims are available:






If the size of shim required is larger than that listed in the table, two shims totaling the correct value can be installed. When doing this, insert the thicker shim first.

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

- Remove the transmission housing.






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

A Counter support (Kukko 22/2)
B Internal Puller 46 to 58 mm (Kukko 21/7)

- Insert the shim(s) of the determined thickness, with the thicker shim inserted first.

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