Volkswagen Golf Variant / Jetta. Manual - part 540

mission housing
A - for example Puller - Kukko Counterstay - 22/2-
B - for example Puller - Kukko Internal - 46-56mm - 21/7-

Installing the outer race/tapered roller bearing into the transmis‐

sion housing.
– Support the transmission housing directly under the bearing

mount using the Press Piece - Bushing - 3259- .

– See if a shim S1 must be inserted under the outer race. Refer

to

⇒ Fig. ““Shim S1 for the outer race/tapered roller bearing is

deleted as of production date 04/12/2006.”“ , page 179

 .

– If necessary, place a 1 mm shim S1 under the outer race.

Removing the Bearing Inner Race/Taper Roller Bearing

Installing the Bearing Inner Race/Taper Roller Bearing

WARNING

Wear safety gloves.

– Heat inner races/tapered roller bearing inner race to approxi‐

mately 100 °C (212 °F) before installing.

– Support the bearing inner race on the on opposite side with

the Press Piece - Multiple Use - VW455- .

The shoulder of the Press Piece - Multiple Use - VW455- points

to the differential housing.

176

housing
B - for example Puller - Kukko Internal - 46-56mm - 21/7-
– Tension internal puller securely behind tapered roller bearing

inner race.

Installing outer race/tapered roller bearing into the clutch housing
– Support clutch housing directly beneath bearing mount using

Bearing Installer - Wheel Bearing - 3345- .

Removing the bearing inner race/taper roller bearing
– Before installing the puller, place the Press Piece - Multiple

Use - VW472/2- und Press Piece - Output Shaft Gear/Final

Drive Gear - 3002- on the differential housing.

Installing the Bearing Inner Race/Taper Roller Bearing

WARNING

Wear safety gloves.

– Heat inner races/tapered roller bearing inner race to approxi‐

mately 100 °C (212 °F) before installing.

2. Differential    

177

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.

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

secure it with a new spring pin.

2.2

Differential, Adjusting

Special tools and workshop equipment required
♦ Measuring Set - Magnetic Plate - 50mm - VW385/17-
♦ Dial Gauge Holder - VW387-
♦ Press Plate - VW401-
♦ Press Plate - VW402-
♦ Press Piece - Rod - VW408A-
♦ Press Piece - Rod - VW412-
♦ Press Piece - Multiple Use - VW510-
♦ Press Piece - Multiple Use - 30-14-
♦ Press Piece - Front Control Arm - 2040-
♦ Press Piece - Bushing - 3259-
♦ Bearing Installer - Wheel Bearing - 3345-
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Press Piece - Multiple Use - 30-205-
♦ Dial Gauge
A new differential adjustment is required when the following com‐

ponents have been replaced:
♦ Transmission Housing
♦ Clutch Housing
♦ Differential housing
or the

178

production date 04/12/2006.
The outer race/tapered roller bearing seat has been adapted.
– Measure the bearing seat depth in the transmission housing

for the outer race/tapered roller bearing.

Dimension -a-

Shim S1

15.2 mm

No

16.2 mm

Yes

Continuation for All

– Install the outer race/tapered roller bearing into the transmis‐

sion housing, if necessary, with a 1 mm shim S1.

Note

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

Do not interchange them.

– Install the tapered roller bearing inner race (opposite drive

gear side) without adjustment shim into the clutch housing.

– Insert the differential into the transmission housing.
– Position clutch housing and tighten 5 bolts to the tightening

specification. Refer to

⇒ “6.4 Overview - Clutch Housing, Removing and Installing”,

page 115

 .

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

to“0” with 1 mm preload.

A - 30 mm dial gauge extension
– Move differential up and down, read off play on dial gauge and

note. (Example: 1.50 mm)

2.3

Differential Shim S2, Selecting

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

pre-load figure of 0.35 mm to the reading obtained for S2.
Example:

Measured value

1.50 mm

2. Differential    

179