Get FinalDriveandDifferential -> 5.3 Differential, Adjusting Guide for Volkswagen Golf 4 Door Fifth Generation (2003-2008)

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

Installing the Differential Bevel Gears

– Insert thrust washer union with transmission fluid.

– Install and secure both large differential planetary gears, for

example, with a flange shaft.

– Insert the small differential planetary gears 180° offset and

pivot them into position.

– Press the differential bevel gear axle -arrow A- up to the first

small differential bevel gear.

– Insert threaded pieces -arrow B- into the large differential

planetary gears.

•

Installed position: shoulder faces the differential bevel gear

– Install the differential bevel gear axle up the end position and

secure it with a new spring pin. Refer to

⇒ Fig. ““Roll Pin, Installing”“ , page 405 .

Roll Pin, Installing

– Drive new roll pin -arrow- flush into differential bevel gear axle

with a drift -1-.

5.3

Differential, Adjusting

⇒ “5.3.1 Determining the Shim”, page 406

Special tools and workshop equipment required

♦ Measuring Set - Magnetic Plate - 50mm - VW385/17-

♦ Dial Gauge Holder - VW387-

♦ Press Plate - VW402-

♦ Press Piece - Rod - VW408A-

♦ Press Piece - Multiple Use - 3005-

♦ Press Piece - Bushing - 3259-

♦ Bearing Installer - Wheel Bearing - 3345-

♦ Puller - Kukko Internal - 46-56mm - 21/7-

♦ Puller - Kukko Counterstay - 22/2-

♦ Dial Indicator - VAS6080A-

♦ 30 mm dial gauge extension

A new differential adjustment is required when the following com‐

ponents have been replaced:

♦ Transmission Housing

♦ Clutch Housing

♦ Differential housing or

♦ Differential tapered roller bearing

5. Differential

405

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

Adjustment overview. Refer to

⇒ “4 Overview - Adjustment”, page 393 .

– Pressing outer race/tapered roller bearing with shim into clutch

housing.

Note

♦ Pay attention to the installed position of the shim.

♦ The collar on the inner circumference faces the seal.

– Press the outer race/tapered roller bearing without the shim

into transmission housing.

– Insert differential into clutch housing.

– Position the transmission housing and tighten the 5 bolts to

the tightening specification -item 13- ⇒ Item 13 (page 230) and

-item 14- ⇒ Item 14 (page 230) .

– Push the differential toward the clutch housing and rotate eight

times at the same time.

– Press differential in direction of transmission housing and ro‐

tate eight times at the same time.

– Attach the gauge to the transmission housing and set it to “0”

with 1 mm of pretension.

A - 30 mm dial gauge extension

– Move the differential up and down and read the play on the

dial gauge and note it (example: 0.70 mm).

5.3.1

Determining the Shim

The specified bearing pre-load is obtained by adding a constant

pre-load figure of 0.25 mm to the reading obtained.

Example

Measured value

+ Preload (constant value)

Adjusting shim thickness =

0.70 mm

0.25 mm

0.95 mm

– Remove the transmission housing.

406

Rep. Gr.39 - Final Drive and Differential

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

– Remove the tapered roller bearing outer race from the trans‐

mission housing.

A - Counter Support , for example, Puller - Kukko Counterstay -

22/2-

B - Internal Puller 46 to 58 mm , for example, Puller - Kukko In‐

ternal - 46-56mm - 21/7-

– Shim part number. Refer to the Parts Catalog.

– Install the shim with the correct thickness, thickest shim first.

The following shims are available:

Shim Thickness (mm)

0.65

0.70

0.75

0.80

0.85

0.90

0.95

1.00

1.05

1.10

1.15

1.20

1.25

If the measured shim thickness is larger than those listed in the

table, then install two shims that add up to the necessary thick‐

ness. Insert the thicker shim first.

Tolerance variations make it possible to find the exact shim thick‐

ness required.

– Install the outer race and the transmission housing and tighten

to the tightening specification -item 13- ⇒ Item 13 (page 230)

and -item 14- ⇒ Item 14 (page 230) .

5. Differential

407

FinalDriveandDifferential -> 5.3 Differential, Adjusting for Your Volkswagen Golf 4 Door Fifth Generation (2003-2008)

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