Adjusting crown wheel: VW Passat B5

🧭 Before you start

Fits: VW Passat B5 (3B)

• Special tools named: dial gauge

Don't miss

• As a test condition, a temporary shim S2 of 1.20 mm is installed. It is referred to below as S2*. After backlash is determined, S2* is replaced with final shim S2.
• After backlash is determined, temporary shim S1* is replaced with final shim S1.The total shim thickness "“S"total” remains unchanged.
• Shim allocation Electronic parts catalogue "“ETKA”"

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📋 Procedure

1. Pull out flange shaft oil seal using oil seal extractorVW 681.
2. Remove differential tapered roller bearing outer races and remove shims .
3. Drive outer race for taper roller bearing with shim S2into gearbox housing. For measurements, a shim S2 1.20 mm thick (2 shims of 0.60 mm) is used. [Note: As a test condition, a temporary shim S2 of 1.20 mm is installed. It is referred to below as S2*. After backlash is determined, S2* is replaced with final shim S2.]
4. Press outer race for tapered roller bearing without shim into cover for differential.
5. Install differential in housing without speedometer drive wheel.

6. Fit cover and tighten bolts to 25 Nm. — 25 Nm (18 lb-ft)
7. Turn gearbox so that differential cover faces upwards.
8. Turn differential 8 turns in both directions so that tapered roller bearings settle.
9. Place end measuring plateVW 385/17 on differential gear.
10. Set up measuring tools.
11. Set dial gauge extension on centre of end measuring plateVW 385/17.
12. Set dial gauge (3 mm range) to zero with 2 mm preload.
13. Move differential back and forth with crown wheel adjusting toolVW 521(direction of arrow).
14. Read play on dial gauge. [Note: After backlash is determined, temporary shim S1* is replaced with final shim S1.The total shim thickness "“S"total” remains unchanged.] [Note: Shim allocation Electronic parts catalogue
15. Differential with crown wheel: S1* is installed on the cover side and S2*, on the gearbox side.
16. Fit final drive cover and tighten bolts to specified torque .
17. Turn differential several times in both directions so that tapered roller bearings settle.
18. Set up measuring tools.
19. Use dial gauge extensionVW 382/10 (6 mm flat).
20. Turn crown wheel to stop. Set dial gauge to zero, turn crown wheel back and read backlash. Note reading.
21. Repeat measurement three times, turning crown wheel 90° each time. Add the four results and calculate the average backlash. [Note: Shim allocation Electronic parts catalogue
22. Various tolerances make it possible to obtain the exact shim thickness required. [Note: Shim allocation Electronic parts catalogue
23. Various tolerances make it possible to obtain the exact shim thickness required.
24. It must be 0.12...0.22 mm.
25. Measure thickness (a) of old and new input gears in vicinity of tapered roller bearing and determine difference.

Other VW procedures

• Removing engine · 41 torque figures
• Removing and installing camshaft – VW Golf Cabriolet · 47 torque figures
• Adjusting valve timing – VW Passat B5 · 83 torque figures
• Removing and installing camshafts – VW Passat B6 · 39 torque figures
• Removing and installing coolant pump · 53 torque figures
• Leak-proofness of the steering system - check
• Differential - disassemble and assemble
• 4 - Speed automatic gearbox 001 — 1st to 3rd gear clutch -K1-: disassemble and assemble
• 4 - Speed automatic gearbox 001 — 3rd and 4th gear clutch -K3-: disassemble and assemble
• Rear wheel outer bearing - regulate · 1 torque figures