Differential, Adjusting

WARNING: This page is about a different car, the 2013 Volkswagen Beetle and 2012 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

Special Tools And Workshop Equipment Required

Magnetic Plate 50 mm Dia. VW 385/17
Dial Gauge Holder VW 387
Punch VW 407
Thrust Pad 30-205
Torque Wrench 1331 5-50 Nm VAG 1331
Puller - Kukko Internal - 46-56mm 21/7
Puller - Kukko Counterstay 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 .

Procedure

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

NOTE:

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.

-- Mount the transmission housing and tighten the five bolts to the tightening specification.

-- Attach the dial gauge holder VW 387 and set the dial gauge 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 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

Example:

Bearing clearance measured value	Adjustment shim thickness according to the table
0.70 mm	0.95 mm

Adjustment Shim Table

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

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

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

A -

Counter support, for example, Puller - Kukko Counterstay 22/2

B -

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

-- Insert the shim with the correct thickness.

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

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

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

Tightening Specifications

Transmission housing to clutch housing, refer to TRANSMISSION HOUSING AND SHIFT MECHANISM OVERVIEW .