Component Disassembly & Reassembly: Differential: Reassembly

1. Inspect all components for wear or damage and replace as necessary. If roller bearings were removed, heat to 212°F (100°C), and press into position using a press and supports.
   NOTE: If unit is not equipped with spacer sleeve, or if components other than pinion shaft or roller bearings have been replaced, axial play must be checked and adjusted.
2. To check axial play, install side gear with short shaft and both large thrust washers in differential cover. Place assembly in a vise and clamp gear tight against cover.
3. Install side gear with long shaft in housing. Place sleeve on machined surface of side gear with short shaft. Position differential housing on cover. Install and tighten 4 bolts pulling housing into place on cover.
   Fig 1: Exploded View of Clutch Housing

   Courtesy of VOLKSWAGEN UNITED STATES, INC.
   Fig 2: Exploded View of Differential Assembly

   Courtesy of VOLKSWAGEN UNITED STATES, INC.
4. Install a gauge bar with a dial indicator to end of drive gear shaft in housing. Dial indicator plunger must contact differential housing neck. Press down on side gear shaft and zero dial indicator with .080" (2 mm) preload.
5. Move side gear up and down to determine axial play. Play should be .001-.007" (.03-.17 mm). See Fig 3 . If not to specifications, install a spacer of correct size to obtain specified play.
6. Recheck play after installing correct spacer. Spacers are available in the following lengths: 31.84 mm, 31.93 mm, 32.02 mm, 32.11 mm, and 32.20 mm.

Fig 3: Measuring Differential Gear Axial Play

Courtesy of VOLKSWAGEN UNITED STATES, INC.