Differential, Adjusting

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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
Thrust Pad 3005
Tube 3259
Press Tube 3345
Torque Wrench (5-50 Nm) VAG 1331
Kukko Extractor 46-58 mm 21/7
Kukko Support 22/2

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 .

-- Press the outer race/tapered roller bearing with shim -item 8- in DIFFERENTIAL OVERVIEW into the clutch housing.

Fig 1: Identifying Outer Race/Tapered Roller Bearing Pressed Into Clutch Housing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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 the transmission housing.

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Insert the differential into the clutch housing.

-- Position the transmission housing and tighten the 5 bolts to specification. Refer to -items 13 and 14- in TRANSMISSION HOUSING AND SHIFT UNIT OVERVIEW .

-- Press the differential in the direction of the clutch housing and rotate 8 times at the same time.

-- Press the differential in the direction of the transmission housing and rotate 8 times at the same time.

-- Install the measuring tools to the transmission housing.

-- Set the dial gauge with a 1 mm preload to "0".

Fig 3: Identifying Dial Gauge

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

A -

30 mm dial gauge extension

-- Move the differential up and down, read off the play on the dial gauge and make a note of it (example: to 0.70 mm).

Determining the Shim Thickness

The specified bearing preload is obtained by adding a constant preload 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. Refer to:

With CCTA, CBFA, CPLA, CPPA Engines, refer to TRANSMISSION, REMOVING .
With CJAA, CVCA Engines, refer to TRANSMISSION, REMOVING .

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

Fig 4: Identifying Outer Race/Tapered Roller Bearing Pulled 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. If more than one shim, install the thickest shim first.

The following adjusting shims are available:

Adjusting 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. Install the thickest shim first.

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

-- Install the outer race and the transmission housing and tighten to specification. Refer to -items 13 and 14- in TRANSMISSION HOUSING AND SHIFT UNIT OVERVIEW .

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Tightening Specifications

Transmission housing to clutch housing. Refer to TRANSMISSION HOUSING AND SHIFT UNIT OVERVIEW .