Differential, Adjusting

Differential, Adjusting

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 Tube (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 the differential tapered roller bearing

Adjustment overview, refer to => [ Adjustment Overview ] Adjustment Overview.

- Press the outer race/tapered roller bearing with washer (- item 8 - in the => [ Differential Overview ] Description and Operation) into clutch housing.






• Pay attention to the washer installed position.

• The collar on the inner circumference faces the seal.

- Install the outer race/tapered roller bearing without an 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 - items 13 and 14 - in the => [ Transmission Housing and Gear Shift Unit Overview ] Transmission Housing and Gear Shift Unit Overview.

- 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.

- Attach the measuring tools to the transmission housing.

- Set the dial gauge with a 1 mm preload to "0".






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).

Shim, Selecting

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.

- Removing the outer race/tapered roller bearing from the transmission housing






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

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

- Insert the shim of the correct thickness.

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 to bolts to specification, see - items 13 and 14 - in the => [ Transmission Housing and Gear Shift Unit Overview ] Transmission Housing and Gear Shift Unit Overview.