Lubricate bearings with hypoid gear oil.

A-Standard torque meter, 0 to 600 Ncm (0 to 0.44 ftlb).


The ring gear must be adjusted if

Transmission housing, Final drive cover, Tapered roller bearings for differential, Pinion/ring gear set are replaced (see also "Necessary Adjustments").

Determining Total Shim Thickness "Stot" (SI plus S2)

(For determining preloading of tapered roller bearings on differential)

1. Remove drive pinion.

2. Remove seals for shaft flanges.

5. Place differential in housing. Installation position: ring gear leading into housing.

6. Mount cover and tighten bolts crosswise to a torque of 24 Nm (17.7 ftlb).

7. Clamp transmission in assembly stand with cover facing up.

3. Remove outer rings of tapered roller bearings for differential. Remove shims.

4. Drive in tapered roller bearing outer races without shims against stop.

A - Dial gage extension approx. 30 mm

8. Place end gage plate VW 385/17 on collar of differential.

9. Mount universal dial gage holder VW 387 with dial gage and extension on housing and set dial gage to 0 with 1 mm pre-1oading.

10. Move differential up and down, read and note play on dial gage (e.g. 1.42 mm).

11. Install shims with total shim thickness "Stot" determined (in this example 1.92 mm) behind tapered roller bearing outer race end cover (S2 side). Lubricate both tapered roller bearings with hypoid oil.

12. Remount cover.

13. Guide adjusting device VW 521/4 together with sleeve VW 521/8 into neck of differential, and clamp.

A - Standard torque meter, 0 to 600 Ncm (0 to 4,4 ftlb)

C - Adjusting device 521/4

14. Place 0 to 600 Ncm (0 to 4,4 ftlb) torque meter on adjusting device and turn slowly and evenly. The friction torque of new tapered roller bearings should be at least 250 Ncm (1,8 ftlb).

It is not necessary to measure friction torque of used tapered roller bearings.

A - Dial gage extension approx. 30 mm


Do not turn differential while measuring play, as this will falsify results.

"Stot" = Measured value + loading

Measured value (example) 1.42 mm Loading (constant value) +0.50 mm

1.92 mm


When adjusting the pinion/ring gear set, adjust and check drive pinion at same time.

3. Carefully turn differential counterclockwise with adjusting device VW 521/4 until ring gear rests on drive pinion.

A d j u lash sting Back-

4. At this point, set dial gage to 0 with 2 mm preloading.

Prerequisite: drive pinion adjusted and installed with S3 and S4.

Turn differential several times to preload and settle tapered roller bearings.

1. Place adjustable lever VW 388 on adjusting device VW 521/4. Lever length via large hexagon surface is 79 mm to upper edge of ball.

2. Apply universal dial gage holder with dial gage and extension so that there is a right angle between the dial gage axis and the lever.

5. Turn differential clockwise until ring gear comes to rest against the opposite flank of the next drive pinion tooth. Read off and note backlash.

6. Repeat measurement procedure three times, turning ring gear 90° further each time.

7. Add up the four measured values and calculate mean backlash.

Determining Mean Backlash


1st measurement 0.84 mm

2nd measurement 0.85 mm

3rd measurement 0.84 mm

4th measurement 0.83 mm sum 1 Twma

Mean backlash = 3.36 : 4 = 0.84 mm a = approx. 79 mm


The following shims are available:

If measured values deviate from each other by more than 0.06, the installation of the ring gear or the pinion/ring gear set is not correct. Check installation, replacing pinion/ring gear set if necessary.

Replacement Part No.

Thickness (mm)

113 517 201



113 517 202



113 517 203



113 517 204



113 517 205



113 517 206



113 517 207



113 517 208



113 517 209



113 517 210



113 517 211


+ Lift (axial displacement of ring gear from play-free gear mesh to attain backlash)

It is possible to measure exact shim thicknesses due to differing tolerances.

- Measured mean backlash

Determining Shim Stot = Total shim thickness Thickness SI (Ring Gear

Lift = 0.15 mm (constant value)

Example: Example:

Stot 1.92 mm Stot 1.92 mm

S2 1.23 mm

The following shims are available:

It is possible to measure exact shim thicknesses due to the differing tolerances.

Measure thickness of shims at several different points with a micrometer. In addition, check shims for burrs and damage.

Install only shims in perfect condition!

Install shims SI and S2 as determined.

Check Measurement

Measure backlash on periphery four times. It should be:


The individual measurement results must not deviate from each other by more than 0.05 mm.

Replacement Part No.

Thickness (mm)

018 409 381

018 409 383

018 409 385

018 409 387

018 409 389

018 409 391

018 409 393

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