Volkswagen Golf / Golf GTI / Golf Variant. Manual - part 536

Heat the Inner Race/Tapered Roller Bearing and Press On It
The cage wit the tapered rollers must rotate easily when being

installed.

WARNING

Wear safety gloves.

Removing the Inner Race/Tapered Roller Bearing
A - Puller , for example, -18/1-
B - Puller , for example, -17/1-

Heat the Inner Race/Tapered Roller Bearing and Press On It
The cage wit the tapered rollers must rotate easily when being

installed.

WARNING

Wear safety gloves.

Removing the Outer Race/Tapered Roller Bearing from the

Transmission Housing
A - Counter Support , for example, -Kukko 22/2-
B - Internal Puller 46 to 58 mm , for example, -Kukko 21/7-

Note

Instead of the -21/7- the -21/8- can also be used.

Installing Outer Race/Tapered Roller Bearing into the Transmis‐

sion Housing
– Support the transmission housing directly under the bearing

mount using the - 3345- .

Removing the Spring Pin for the Differential Bevel Gear Axle
– Use a 5 mm diameter drift -B- to remove the adapter sleeve

-A- from the hole -arrow- on the differential housing.

Note

♦

If there is no hole -arrow- on the differential housing, remove

the adapter sleeve as follows:

♦

Cover the inner race/tapered roller bearing in order to prevent

possible damage and entry of shavings.

♦

Remove the adapter sleeve using a chisel.

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: Collar toward 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. ““Installing the Spring Pin for the Differential Bevel Gear

Axle”“ , page 218

 .

Installing the Spring Pin for the Differential Bevel Gear Axle
– Align the hole in the differential bevel gear axle to the hole in

the differential housing.

– Using a drift, install the adapter sleeve -1- to the dimension

-a- = 2.5 ± 0.5 mm.

2.3

Differential, Adjusting

Special tools and workshop equipment required
♦ Transmission Support - VW353-
♦ 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-
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Puller - Kukko Internal - 46-56mm - 21/7-
♦ Counter Support - VAS251623-
♦ Puller - Kukko Counterstay - 22/2-
♦ Dial Indicator - VAS6080A-
♦ 30 mm Dial Gauge Extension
A New Differential Adjustment is Required When the Following

Components Have Been Replaced:
♦ Transmission Housing
♦ Clutch Housing
♦ Differential housing or
♦ Differential tapered roller bearing
Adjustment Overview. Refer to

⇒ “3 Adjustment Overview”, page 221

 .

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

housing -Item 8- 

⇒ Item 8 (page 213)

 .

Note

♦

Pay attention to the shim installed position.

♦

The collar on the inner circumference faces the seal.

– Install the outer race/tapered roller bearing without adjustment

shim into transmission housing.

– Insert differential into clutch housing.
– Mount transmission housing and tighten five bolts.
– Press differential in direction of 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 measuring tools to the transmission housing.
– Set the dial gauge with 1 mm pretension to “0”.
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).

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

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

Measured value

0.70 mm

+ Preload (constant value)

0.25mm

= Shim thickness

0.95 mm

– Remove the transmission housing.

– Removing the outer race/tapered roller bearing from the trans‐

mission housing

A - Counter Support , for example, -22/2-
B - Internal Puller 46 to 58 mm , for example, -21/7-
– For the correct part number. Refer to the Parts Catalog.
– Insert shim with the correct thickness.
The following shims are available:

Shim Thickness (mm)

0.65

0.85

1.05

1.25

0.70

0.90

1.10

 

0.75

0.95

1.15

 

0.80

1.00

1.20

 

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. Install the thicker shim first.
Tolerance variations make it possible to find the exact shim thick‐

ness required.