Differential, Adjusting

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Special tools and workshop equipment required

Dial Gauge Holder VW 387
Magnetic Plate 50 mm Dia. VW 385/17
Punch VW 407
Thrust Pad 30-205
Torque Wrench (5-50 Nm) V.A.G 1331
Kukko Extractor 46-58 mm 21/7
Kukko Support 22/2
Dial Gauge

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 .

-- Press the tapered roller bearing outer race into the transmission housing without a shim, using the thrust pad 30-205. Refer to Figure.

NOTE:

The bearing inner and outer races of the tapered roller bearing are paired. Do not interchange them.

-- Press the tapered roller bearing outer race into the clutch housing, using the thrust pad 30-205. Refer to Figure.

-- Insert the differential into the clutch housing.

-- Install the transmission housing and tighten the five bolts to 25 Nm.

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

Fig 1: Identifying Special Tools VW 387 & VW 385/17

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Move the differential up and down, read off the play on the dial gauge and note. Example: to 0.70 mm).

Determining Shim Thickness

Example:

Bearing Clearance Measured Value	Adjustment Shim Thickness According to the Table
0.70 mm	0.95 mm

Adjustment Shim Table

Bearing Play	Adjusting Shim
Measured value (mm)	Thickness (mm)
0.303 ••• 0.449 0.450 ••• 0.499 0.500 ••• 0.549	0.650 0.700 0.750
0.550 ••• 0.599 0.600 ••• 0.649 0.650 ••• 0.699	0.800 0.850 0.900
0.700 ••• 0.749 0.750 ••• 0.799 0.800 ••• 0.849	0.950 1.000 1.050
0.850 ••• 0.899 0.900 ••• 0.949 0.950 ••• 0.999	1.100 1.150 1.200
1.000 ••• 1.049 1.050 ••• 1.099 1.100 ••• 1.149	1.250 1.300 1.350
1.150 ••• 1.199	1.400

NOTE:

-- Remove the transmission housing and remove the tapered roller bearing outer race from the transmission housing.

Fig 2: Pulling Outer Race/Tapered Roller Bearing Out Of Transmission Housing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Install the shim with the correct thickness, thickest shim first.

If the measured shim thickness is larger than those listed in the table, then install two shims that add up to the necessary thickness.

Tolerance variations make it possible to find the exact shim thickness required.

-- Install the tapered roller bearing inner race again, refer to Figure and install the transmission housing.