Differential, Adjusting: Procedure

WARNING: This page is about a different variant/trim than selected.

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

Transmission Housing
Clutch Housing
Differential housing or
Differential tapered roller bearing

Adjustment Overview. Refer to ADJUSTMENT OVERVIEW .

-- Pressing outer race/tapered roller bearing with shim into clutch housing.

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NOTE:

Pay attention to the shim installed position.

The collar on the inner circumference faces the seal.

-- Install the outer race/tapered roller bearing without adjustment shim into transmission housing.

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-- Insert differential into clutch housing.

-- Position the transmission housing and tighten the 5 bolts to the tightening specification.

-- Push the differential toward the clutch housing and rotate eight times at the same time.

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

-- Attach the gauge to the transmission housing and set it to "0" with 1 mm of pretension.

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A - 30 mm dial gauge extension

-- Move the differential up and down and read the play on the dial gauge and note it (example: 0.70 mm).

Determining The Shim

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
+ Preload (constant value)	0.25 mm
Adjusting shim thickness =	0.95 mm

-- Remove the transmission housing.

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

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A - Counter Support, for example, Puller - Kukko Counterstay :Kukko 22/2

B - Internal Puller 46 to 58 mm, for example, Puller - Kukko Internal - 46-56mm :Kukko 21/7

-- For the correct part number.

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

The following adjusting shims are available:

Shim Thickness (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	-

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 again and the tighten the transmission housing to the tightening specification.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.