Volkswagen Golf Variant / Jetta. Manual - part 202

ponents have been replaced:
♦ Transmission Housing
♦ Clutch Housing
♦ Differential housing
or the
♦ Differential tapered roller bearing
Adjustment Overview. Refer to

⇒ “2 Adjustment Overview”, page 262

Perform the following procedure:
– Press tapered roller bearing outer race into transmission hous‐

ing without shim, using Press Piece - Multiple Use - 30 - 205- .

Refer to

⇒ Fig. ““Installing the Outer Race/Tapered Roller Bearing into

the Transmission Housing.”“ , page 267

Note

Bearing inner- and outer race of tapered roller bearing are paired.

Do not interchange them.

– Press outer race/tapered roller bearing into the clutch housing

using the Press Piece - Multiple Use - 30 - 205- . Refer to

⇒ Fig. ““Installing Outer Race/Tapered Roller Bearing into the

Clutch Housing”“ , page 266

– Insert differential into clutch housing.
– Mount the transmission housing and tighten the five bolts to

25 Nm.

– Attach the Dial Gauge Holder - VW387- and set the dial gauge

to“0” with 1 mm preload.

– Move differential up and down, read off play on dial gauge and

note. (example: 0.70 mm).

3.2.1

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

0.70 mm

+ Preload (constant value)

0.25 mm

270

0.95 mm

Example:

Bearing clearance measured

value

Adjustment shim thickness ac‐

cording to the table

0.70 mm

0.95 mm

Shim Table

Bearing play

Shim

Measured value

(mm)

Thickness

(mm)

0.303 to 0.449

0.450 to 0.499

0.500 to 0.549

0.650

0.700

0.750

0.550 to 0.599

0.600 to 0.649

0.650 to 0.699

0.800

0.850

0.900

0.700 to 0.749

0.750 to 0.799

0.800 to 0.849

0.950

1.000

1.050

0.850 to 0.899

0.900 to 0.949

0.950 to 0.999

1.100

1.150

1.200

1.000 to 1.049

1.050 to 1.099

1.100 to 1.149

1.250

1.300

1.350

1.150 to 1.199

1.400

Note

Allocate the shims. Refer to the Parts Catalog.

– Remove the transmission housing and remove the tapered

roller bearing outer race from the transmission housing.

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

Kukko 22/2-
B - Internal Puller 46 to 58 mm , for example, Puller - Kukko In‐

ternal - 46-56mm -Kukko 21/7-
– Install the shim with the correct thickness, thickest shim first.
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.
Tolerance variations make it possible to find the exact shim thick‐

ness required.
– Install the tapered roller bearing inner race again (refer to

⇒ Fig. ““Installing the Outer Race/Tapered Roller Bearing into

the Transmission Housing.”“ , page 267

) and install the trans‐

mission housing.

3. Differential

271