Adjusting differential: Gearbox codes FNT, FLU, GAH — VW

Adjusting differential: Gearbox codes GEQ, GSE, GEW, GSG => Page
39-55
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Special tools and workshop equipment required

VW 385/17 Final measurement plate
VW 387 Universal dial gauge bracket

Special tools and workshop equipment required

VW 401 Thrust plate
VW 402 Thrust plate
VW 408 A Press tool
VW 412 Press tool

Special tools and workshop equipment required

VW 510 Press disk
30-14 Escape hose
40-21 Drive sleeve
3259 Hose
3345 Hose
1 - Kukko 21/7 Internal extractor

The differential should always be adjusted when one of the following parts is changed:

Gearbox housing
Clutch housing
Differential cage

or the

Differential conical roller bearings

are changed.

Fit the external ring of the conical roller bearing (sprocket side), with the adjusting washer S1 (always 1 mm thick), to the gearbox housing.

Note:

The internal and external rings of the conical roller bearing come in pairs. Do not confuse them!

Fit the external ring of the conical roller bearing (opposite side from sprocket) to the clutch housing without the adjusting washer.
Place the differential into the gearbox housing.
Place the clutch housing on top and tighten 5 screws with their corresponding tightening torques.

Place dial gauge and measuring tool on top (measurement range of 3 mm, prolongation -A- of dial gauge, some 30 mm).
Set dial gauge to "0" with 1 mm of pretension.
Move the differential up and down, read the play in the gauge and note it down.
(Example: 1.50 mm)

Adjusting washer S2

The necessary pretension for the socket is achieved by adding a constant pressure value (0.35mm) to the value obtained during the measuring for S2.

Example:

Measured value · 1.50 mm
+ Pressure (constant value) · 0.35 mm
Thickness of washer S2 = · 1.85 mm

Remove the housing from the clutch and uncouple the external ring from the conical roller bearing -A-.

B - Internal puller 46...58 mm, e.g. Kukko 21/7

Fit adjusting washer S2 of corresponding thickness (in example, 1.75 mm) and replace the conical roller bearing external ring in the clutch housing.

The following adjusting washers are available:

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

The existence of different tolerances allows the exact thickness of the washer to be calibrated.

If the required thickness of the adjusting washer is greater than indicated in the table, two washers can be fitted where the combined thickness is equivalent to that required.

Place the clutch housing on top and tighten the screws with their corresponding tightening torques.