Special tools and workshop equipment required

• End dimension plate - VW 385/17-
• Universal dial gauge bracket - VW 387-
• Tightening plate - VW 402-
• Tightening plate - VW 401-
• Die - VW 408-
• Die - VW 412-

• Thrust plate - 30-205-
• Tube for releasing - 30-14-
• Tube element - 2040-
• Pipe - 3259-
• Torque wrenches - V.A.G 1331-
• Not suitable: tools 1-4
• Dial gauge - VAS 6080A-

• Internal puller - VAS 251 615- or, e.g. internal puller - Kukko 21/7-

It is necessary to readjust the differential when the following components are renewed:

• Gearbox housing
• Clutch housing or
• Differential cage

or the

• Differential tapered roller bearing

• Insert the outer ring of the roller bearing (crown side) into the gearbox casing

Note Inner and outer tapered roller bearing races are paired. Do not interchange!

• Press tapered roller bearing outer race (opposite gear wheel) with no shim into gearbox housing.
• Insert differential in gearbox housing.
• Fit clutch housing and tighten 5 bolts to specified torque.

• Fit the gauge and set to "0" with a pretension of 1 mm.

A - 30 mm gauge extension

• Set dial gauge to "0" with 1 mm preload for bearing.
• Move the differential up and down while reading the measurement on the gauge and noting the results (for example: 1.50 mm raised).

Determining thickness of shim.

The specified bearing preload is obtained by adding a constant value for preload (0.35 mm) to the reading obtained.

As an example:

• Remove clutch housing and press out tapered roller bearing outer race -A-.

B - Internal puller - VAS 251 615- , or e.g. -Kukko 21/7-

• Allocate the shim(s) using - Electronic parts catalogue (ETKA) .

The existence of different thickness shims will enable the selection of the correct thickness required.

If the size of the shim required is larger than those listed in - Electronic spare parts catalogue (ETKA) install two shims amounting to the correct value.

• Fit the shim of right thickness (for this example 1.85 mm) and reinsert the outer ring of the conical bearing into the clutch housing.
• Fit clutch housing and tighten bolts.

Specified torques

• Gearbox housing to clutch housing