Adjusting differential on vehicles with engines of 111 kW and above — VW

Special tools and workshop equipment required

VW 313 Support clamp
VW 385/17 End measuring plate
VW 387 Universal dial gauge bracket
VW 412 Press tool
VW 442 Press piece
VW 456 A Gear carrier support

Special tools and workshop equipment required

VW 457 Support rail
40-105 Thrust plate
2004 Counter-hold
3291/1 From assembly tool 3291
V.A.G 1331 Torque wrench
1 - Kukko 20/10 Two-arm puller

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
39-39
.

Pressing taper roller bearing inner race without shim into the gearbox housing.
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

Take off gearbox housing.
Secure gearbox housing to assembly support with bolts -A-.

Pull taper roller bearing inner race off gearbox housing.

A - Two arm puller e.g. Kukko 20/10.

Insert puller hooks into cut-outs in 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 409 231 / 02G 409 231 A / 02G 409 231 B
0.80 / 0.85 / 0.90 · 02G 409 231 C / 02G 409 231 D / 02G 409 231 E
0.95 / 1.00 / 1.05 · 02G 409 231 F / 02G 409 231 G / 02G 409 231 H
1.10 / 1.15 / 1.20 · 02G 409 231 J / 02G 409 231 K / 02G 409 231 L
1.25 / 1.30 / 1.35 / 1.40 · 02G 409 231 M / 02G 409 231 N / 02G 409 231 P / 02G 409 231 Q
0.70+0.75 = 1.45 / 0.75+0.75 = 1.50 / 0.75+0.80 = 1.55 · 02G 409 231 A + B / 02G 409 231 B + B / 02G 409 231 B + C

Press outer race in again.