Differential, Adjusting

WARNING: This page is about a different car, the 2009 Audi TT and 2008 Audi TT. However, it is still accessible from the selected car via links, so may be relevant.

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

Transmission housing
Clutch housing
Differential housing
Differential tapered roller bearing

List of adjustments, refer to ADJUSTMENT OVERVIEW .

Special tools and workshop equipment 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
Oil Pump Align Plate 3005
Tube 3259
Press Tool 3345
Torque Wrench V.A.G 1331
Dial Gauge VAS 6080
Kukko 21/7 internal puller
Kukko 22/2 counter-support
Dial gauge extension 30 mm

Procedure

-- Press the outer ring for the tapered roller bearing with an adjustment shim into the clutch housing.

The shoulder on the inner diameter of the 3005 points toward the outer ring.

Fig 1: Identifying Outer Race/Tapered Roller Bearing Pressed Into Clutch Housing
Courtesy of AUDI OF AMERICA, LLC

-- Press the outer ring for the tapered roller bearing without an adjustment shim into the transmission housing.

Fig 2: Identifying Tapered Roller Bearing Outer Race Pressed In Transmission Housing

Courtesy of AUDI OF AMERICA, LLC

-- Insert differential into clutch housing.

-- Attach the transmission housing and tighten the 5 bolts to tightening specification -11- TRANSMISSION HOUSING AND SHIFT MECHANISM ASSEMBLY OVERVIEW and -12- TRANSMISSION HOUSING AND SHIFT MECHANISM ASSEMBLY OVERVIEW .

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

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

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

Fig 3: Identifying Dial Gauge

Courtesy of AUDI OF AMERICA, LLC

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.

Example:

Measured value	0.70 mm
+ Pre-load (constant value)	0.25 mm
Thickness of shim =	0.95 mm

-- Remove transmission housing.

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

Fig 4: Identifying Outer Race/Tapered Roller Bearing Pulled Out Of Transmission Housing

Courtesy of AUDI OF AMERICA, LLC

A - Support, for example Kukko 22/2

B - Internal puller 46 to 58 mm, for example Kukko 21/7

-- Determine the adjustment shim thickness according to the table; part numbers.

-- Insert shim of correct thickness.

The following shims are available:

Thickness of Shims in mm
0.65	0.85	1.05	1.25
0.70	0.90	1.10
0.75	0.95	1.15
0.80	1.00	1.20

Different shim thicknesses make it possible to select the required thickness precisely.

If the measured shim thickness is greater than the one listed in the table, two adjustment shims totaling the correct value can be installed. First the thicker adjustment shim must be inserted for this.

-- Press in the outer ring again and fasten the transmission housing. Refer to TRANSMISSION HOUSING AND SHIFT MECHANISM ASSEMBLY OVERVIEW .

Fig 5: Identifying Tapered Roller Bearing Outer Race Pressed In Transmission Housing

Courtesy of AUDI OF AMERICA, LLC