Gearbox removal & installation: Determining total shim thickness "Stotal" for shims "S1" + "S2" — VW

🧭 Before you start

Fits: VW Passat B5 (3B)

• Special tools named: dial gauge

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• 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".
• The tip of the dial gauge must be positioned on centre of differential.
• If the measurement has to be repeated, the differential must first be turned 5 turns in each direction again to settle the tapered roller bearing.

🔩 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 seals using oil seal extractorVW 681.
2. Remove differential tapered roller bearing outer races and remove shims .
3. Drive small tapered roller bearing outer race with shim "S2" into 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 tapered roller bearing outer race into cover for differential without shim "S1".
5. Insert differential without drive wheel for speedometer sender G22 into gearbox housing.

6. Install cover for differential with 4 bolts (25 Nm). — 25 Nm (18 lb-ft)
7. Position gearbox so that differential cover faces upwards.
8. Turn differential 5 turns in both directions to settle tapered roller bearing.
9. Lay measuring plateVW 385/17 on differential.
10. Set up measuring equipment using 30 mm dial gauge extension.
11. Set dial gauge (3 mm range) to zero with 2 mm preload. [Note: The tip of the dial gauge must be positioned on centre of differential.]
12. Lift differential without turning; read play on dial gauge and note. [Note: If the measurement has to be repeated, the differential must first be turned 5 turns in each direction again to settle the tapered roller bearing.] [Note: After backlash is determined, temporary shim "S1*" is replaced with final shim "S1".The total shim thickness "Stotal" remains unchanged.]

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