Differential, Adjusting

Differential, Adjusting

Special tools, testers and auxiliary items required

• Transmission support (VW 353)

• Magnetic plate (VW 385/17)

• Dial gauge holder (VW 387)

• Thrust plate (VW 402)

• Punch (VW 408 A)

• Thrust pad (3005)

• Tube (3259)

• Tube (3345)

• Torque wrench (V.A.G 1331)

• Internal extractor (Kukko 21/7)

• Support (Kukko 22/2)

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

• Transmission housing

• Clutch housing

• Differential housing or

• Tapered roller bearing for differential

List of adjustments --> [ Adjustment Overview ] Adjustment Overview.

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





• Observe installed location of washer, shoulder on inner diameter faces toward seal.

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





- Insert differential into clutch housing.

- Attach transmission housing and tighten 5 bolts to tightening specification --> [ (item 10) Bolt, 15 Nm + an additional 90° (1/4 turn) ] Transmission Housing and Selector Mechanism Assembly Overview and --> [ 11 Bolt, 15 Nm+ an additional 90° (1/4 turn) ] Transmission Housing and Selector Mechanism Assembly Overview.

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

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

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





A Dial gauge extension 30 mm

- Move differential up and down, read the play on dial gauge and note (example 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 transmission housing.

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





A Support, e.g. (Kukko 22/2)
B Internal puller 46 to 58 mm, e.g. (Kukko 21/7)

- Determine part numbers of adjustment shims according to.

- Insert shim of correct thickness, thickest shim first.

The following adjustment shims are available:





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

Varying tolerances make it possible to measure the required shim thickness exactly.

- Press in outer race again and tighten transmission housing to tightening specification --> [ (item 10) Bolt, 15 Nm + an additional 90° (1/4 turn) ] Transmission Housing and Selector Mechanism Assembly Overview and --> [ 11 Bolt, 15 Nm+ an additional 90° (1/4 turn) ] Transmission Housing and Selector Mechanism Assembly Overview.