Adjusting differential for vehicles with engines up to 103 kW — VW

Special tools and workshop equipment required

VW 385/17 End measuring plate
VW 387 Universal dial gauge bracket
VW 402 Thrust plate
VW 408 A Press tool
VW 415 A Tube
VW 473 Thrust piece

Special tools and workshop equipment required

30-14 Tube
2050 Thrust piece
V.A.G 1331 Torque wrench
1 - Kukko 21/8 Internal puller
4 - Kukko 22/2 Counter support

The differential must be adjusted, when

Gearbox housing
Clutch housing
Differential housing

or the

Differential taper roller bearing

have been renewed.

Adjustment overview => Page
39-49
.

Pressing taper roller bearing outer race and oil deflector ring into clutch housing => Page
39-19
.

Note:

Inner and outer taper roller bearing races are a pair. Do not interchange.

Pressing taper roller bearing outer race without shim into the gearbox housing using thrust piece 2050.
Fit differential into clutch housing
Fit gearbox housing and tighten 5 bolts to torque setting.

Mount dial gauge and "0" with 1 mm preload.
Move differential up and down and recall play indicated on dial gauge
(Example: 0.70 mm)

A - 60 mm gauge extension

Note:

Do not turn differential when measuring otherwise the bearing will settle and a false measurement will be given.

Determining shim thickness

The specified bearing preload is obtained by adding a constant figure (0.40 mm) to the reading obtained.

Example:

Reading · 0.70 mm
+ Preload (constant figure) · 0.40 mm
Thickness of shim = · 1.10 mm

Remove gearbox housing and pull taper roller bearing outer race out from gearbox housing.

Insert shims of correct thickness, thickest shim first.

The following shims are available:

Size (mm) · Part No.
0.65 / 0.70 / 0.75 · 02G 409 210 / 02G 409 210 A / 02G 409 210 B
0.80 / 0.85 / 0.90 · 02G 409 210 C / 02G 409 210 D / 02G 409 210 E
0.95 / 1.00 / 1.05 · 02G 409 210 F / 02G 409 210 G / 02G 409 210 H
1.10 / 1.15 / 1.20 · 02G 409 210 J / 02G 409 210 K / 02G 409 210 L
1.25 / 1.30 / 1.35 / 1.40 · 02G 409 210 M / 02G 409 210 N / 02G 409 210 P / 02G 409 210 Q
0.70+0.75 = 1.45 / 0.75+0.75 = 1.50 / 0.75+0.80 = 1.55 · 02G 409 210 A + B / 02G 409 210 B + B / 02G 409 210 B + C

Press outer race in again.