Differential, Adjusting

Differential, adjusting 02Q, 6 Speed FWD M/T





Special tools, testers and auxiliary items required
^ Transmission support VW 353
^ Magnetic plate VW 385/17
^ Dial gauge holder VW 387
^ Pressure plate VW 402
^ Punch VW 408 A
^ Thrust piece 3005





Special tools, testers and auxiliary items required
^ Tube 3259
^ Tube 3345
^ Torque wrench V.A.G 1331
^ - 1 - Internal Puller 46 to 58 mm Kukko 21/7
^ - 4 - Support Kukko 22/2

A new differential adjustment is required when the following components have been replaced:
^ Transmission housing
^ Clutch housing
^ Differential housing or
^ Tapered roller bearing of differential





- Press tapered roller bearing outer race with shim into clutch housing

Note: Note installation position of washer, shoulder on inner diameter points toward sealing ring.





- Pressing outer race/tapered roller bearing without adjustment shim into transmission housing.
- Insert differential into clutch housing.
- Attach transmission housing and tighten 5 bolts to tightening torque and.
- Press differential in direction of clutch housing and rotate eight times at the same time.
- Press differential in direction of transmission housing and rotate eight times at the same time.





- Install dial gauge and set to "0" with 1 mm pre-load.
A - Dial gauge extension 30 mm
- Move differential up and down, read off play on dial gauge and note (example 0.70 mm).

Determining shim thickness
The specified bearing pre-load is obtained by adding a constant pre-load figure of (0.25 mm) to reading obtained.

Example:





- Remove transmission housing.





- Pull outer race/tapered roller bearing out of transmission housing.

A - Support, e.g. Kukko 22/2
B - Internal puller 46 to 58 mm, e.g. Kukko 21/7
- Determine replacement part number of adjustment shim.
- Insert shims of correct thickness, thickest shim first.

The following shims are available:





If size of shim required is larger than that listed in the table, two shims totaling correct value can be installed. First thicker adjustment shim must be inserted for this.

Varying tolerances make it possible to measure required shim thickness exactly.





- Press in outer race again and tighten transmission housing to tightening torque and.