02Q Transmission

Differential. Adjusting

=> [ Determining Shim Thickness ]

Special tools, testers and auxiliary items required

• Transmission Support (VW 353)

• Magnetic Plate 50 mm Dia. (VW 385/17)

• Dial Gauge Holder (VW 387)

• Thrust Plate (VW 402)

• Punch (VW 408 A)

• Thrust Pad (3005)

• Tube (3259)

• Press Tool (3345)

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• Kukko extractor 46-58 mm (21/7)

• Kukko Support (22/2)

A new differential adjustment is required when the following components have been replaced:

• Transmission housing

• Clutch housing

• Differential housing or

• Differential tapered roller bearing

Adjustment overview, refer to => [ Adjustment Overview ] Final Drive, Differential (02Q Manual Transmission).

- Pressing the outer race/tapered roller bearing with shim into the clutch housing.






• Pay attention to the shim installed position.

• The collar on the inner circumference faces the seal.

- Install the outer race/tapered roller bearing without the adjustment shim into the transmission housing.






- Insert the differential into the clutch housing.

- Position the transmission housing and tighten the 5 bolts to specification, see => [ (Item 13) Bolt ] Transmission Component Overviews and => [ (Item 14) Bolt ] Transmission Component Overviews.

- Press the differential in the direction of the clutch housing and rotate it 8 times at the same time.

- Press the differential in the direction of the transmission housing and rotate it 8 times at the same time.

- Install the dial gauge and set it to "0" with a 1 mm preload.






A 30 mm dial gauge extension

- Move the differential up and down, read off the play on the dial gauge and make a note of it (example: to 0.70 mm).

Determining Shim Thickness

The specified bearing preload is obtained by adding a constant preload figure of 0.25 mm to the reading obtained.

Example:






- Remove the transmission housing.

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






A Counter support, for example, Kukko support (22/2)
B Internal puller, for example, Kukko extractor 46-58 mm (21/7)

- For the correct part number, refer to the Parts Catalog.

- Install the shim with the correct thickness, thickest shim first.

The following adjusting shims are available:






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

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

- Install the outer race and the transmission housing and tighten the bolts to specification, see => [ (Item 13) Bolt ] Transmission Component Overviews and => [ (Item 14) Bolt ] Transmission Component Overviews.