Differential, Adjusting

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Fig 1: Identifying Special Tools - Differential, Adjusting (1 Of 2)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools and equipment

VW 353 Transmission support
VW 385/17 End measuring plate
VW 387 Universal dial gauge bracket
VW 402 Thrust plate
VW 408 A Press tool
3005 Press disk

Fig 2: Identifying Special Tools - Differential, Adjusting (2 Of 2)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools and equipment

3259 Tube
3345 Tube
V.A.G 1331 Torque wrench or equivalent
1 - Kukko 21/7 Internal puller
4 - Kukko 22/2 Counter support

The differential must be adjusted, when

Transmission housing
Clutch housing
Differential housing

or the

Differential tapered roller bearing

have been replaced.

Adjustment overview. Refer to Adjustment overview .

Fig 3: Pressing Tapered Roller Bearing Outer Race Into Clutch Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press tapered roller bearing outer race with shim (thickness 0.65 mm) into clutch housing. Refer to Figure .

NOTE: Inner and outer tapered roller bearing races are a pair. Do not interchange.

Fig 4: Pressing Tapered Roller Bearing Outer Race Without Shim Into Transmission Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press tapered roller bearing outer race without shim into transmission housing.
Install differential into clutch housing
Install transmission housing and tighten 5 bolts to torque setting. Refer to Transmission housing and selector mechanism, removing and installing item Transmission housing and selector mechanism, removing and installing .
Press differential in direction of clutch housing and turn it eight times.

Press differential in direction of transmission housing and when doing this turn it eight times.

Fig 5: Measuring Differential Thickness

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Mount dial gauge and zero with 1 mm preload.

A - Dial gauge extension 30 mm

Move differential up and down and recall play indicated on dial gauge (Example: 0.70 mm).

Determining shim thickness

The specified bearing preload is obtained by adding a constant figure (0.30 mm) to the reading obtained.

Example:

Reading	0.70 mm
+ Preload (constant figure)	0.30 mm
Thickness of shim =	1.00 mm

Take off transmission housing.

Fig 6: Pulling Tapered Roller Bearing Outer Race Out Of Transmission Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pull tapered roller bearing outer race out of transmission housing.

A - Counter support, e.g. Kukko 22/2

B - Internal puller 46 to 58 mm, e.g. Kukko 21/7

Insert shims of correct thickness, thickest shim first.

The following shims are available:

Size (mm)	Part No.
0.65 0.70 0.75	02B 409 210 02B 409 210 A 02B 409 210 B
0.80 0.85 0.90	02B 409 210 C 02B 409 210 D 02B 409 210 E
0.95 1.00 1.05	02B 409 210 F 02B 409 210 G 02B 409 210 H
1.10 1.15 1.20	02B 409 210 J 02B 409 210 K 02B 409 210 L
1.25	02B 409 210 M

If the size of shim required is larger than that listed in the table, insert two shims totalling the correct figure.

Varying tolerances make it possible by measuring the shims to obtain the exact shim thickness required.

Fig 7: Pressing Tapered Roller Bearing Outer Race Without Shim Into Transmission Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press outer race in again and tighten transmission housing to torque setting. Refer to Transmission housing and selector mechanism, removing and installing item Transmission housing and selector mechanism, removing and installing .