Inspect the speedometer drive pinion. If the differential bearing located above the pinion needs to be replaced, the speedometer drive pinion must be removed by cutting it with a chisel.
Special tools are required to replace the differential gears or housing, so leave this work to a VAG representative. Internal bearings and differential gears must be adjusted with shims after replacement, and special measuring equipment is required. It may be more economical to replace the entire differential.
Replacing the differential support bearings is possible, but after this it is necessary to adjust their preload.
Replacing bearings and adjusting preload
1. Remove the inner rings of the tapered bearings together with the rollers (figure I:52).
CAUTION: Before removing the bearing remote from the main drive driven gear, remove the speedometer drive gear by cutting it with a chisel (figure I:53).
2. Press on the new speedometer drive gear and new bearings using a metal mandrel. The inner bearing races must be heated to approximately 100°C before installation.
3. Knock out the outer bearing rings from the gearbox housing and clutch housing using a metal drift and remove the 1 mm thick gaskets.
4. Install the same gasket (1 mm) and press the new outer bearing ring into the gearbox housing, installing new oil seals.
5. Press the outer ring of the second bearing into the clutch housing socket.
The original can be found at VWManual.ru
6. Install the differential in the reverse order of removal, tightening the crankcase mounting bolts to the required torque.
7. Install a three-millimeter plate (VAG tool No.385/17) into the clutch housing on the outer bearing of the differential.
b. Install a dial indicator on the clutch housing and place its feeler gauge on a three-millimeter plate. Set the dial indicator scale to zero.
9. Move the differential within the bearing clearance. Note the amount of movement on the dial indicator.
10. To ensure the required bearing preload, install an adjusting shim. Determine the shim thickness as follows: to the measured clearance (axial clearance of the bearing) add a constant number (usually 0.30 mm - the bearing preload value is given in the section "Technical data").
11. Remove the clutch housing, press out the outer bearing race and insert a gasket of the required thickness.
12. Install the collar into the clutch housing socket and check the size again.
13. Assemble the gearbox as described above.
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