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  1. 2005 Touareg
  2. pilot60378

    I originally swapped the carrier shims around the first time I rebuilt it. That caused too much backlash. The .003" backlash was after swapping them back to original position, otherwise backlash was about .030" The situation has now warranted making a solid sleeve with shims instead of crush sleeve with shims to set preload. Next, we are working on making the correct thickness pinion shim. The biggest problem will be making the carrier shims. All we have is a lathe. Any suggestions on making the carrier shims or sources for? Also, checking backlash and gear pattern became a problem with pressing on and off the pinion bearings. We decided to grind the pinion shaft just enough to slide the bearings on and off. Do you foresee any problems with that? I don't feel there is enough centrifugal force to rotate them especially with proper preload. I'm still on the path of proper gear wear pattern.

  3. touaregMY15
    I want to contact you to order a bashplate.
  4. pilot60378
    Hi Mark,

    Did you ever do a wear pattern on your diff? If so, how did yours look? I have about 17lbs-in of pinion preload and my wear pattern is showing toe contact on the coast side (concave) and heel on the drive side (convex). I'm doing this on the bench, so no load on the ring gear. The backlash is .003". Since that's the wear pattern, pinion depth needs to increase. Do you think adding more preload to the pinion might help center the pattern? Any concerns with excessive wear on pinion bearings by doing so?
  5. pilot60378
    I will say thinking about it, on and off throttle did give a little bit of a knock. It seemed more apparent when say going down a hill and feathering the throttle to maintain speed. The knocking was enough force to constantly have to maintain steering a straight line while cruise was in use.
  6. pilot60378
    Hey Mark,

    On the first go at the diff, I never did check the rotational force at the pinion nut. I tightened up the nut until I had maybe .002" play in the hub which was between 40lbs-ft-60lbs-ft if I recall correctly. This time around I'll make sure to measure the turning force. Surprisingly the pinion bearings had no wear after replacing them the first time, so I did not change them out, just installed new races which probably is a waste of time considering how good they look. The carrier races had more wear to them than anything else. However, there are etching lines in them but are not raised. I ran my fingernail across them and nothing snagged so I'm going to reuse them. It seems that the bearing preload is the issue? Off the vehicle on the bench, I turned both axle hubs the same direction, then abruptly changed direction and I could hear the bang/knock. The sound was coming from the pinion area which makes me think that's where the problem was?
  7. pilot60378
    Hi Mark,

    I rebuilt my front diff a little over a year ago. Since then, I had some groan along with a small bang when under light acceleration with light load (more noticeable when cruise is on.) The only parts that I didn't change were, rear pinion bearing race, crush sleeve (obvious reasons) and the needle bearing, which showed no wear. I've got the diff out and opened, I see no wear on the bearings. The races looked pretty good but I decided to install new races in the casing. I've machined a spacer for the crush sleeve just as you stated in your post. Do you think my problem occurred with the preload on the pinion bearings since the crush sleeve was just reused? I plan on mocking up the diff and use blue layout fluid to see how the carrier crown and pinion mesh before final reassembly. Any suggestions? Let me know what your opinion is.

  8. 2005 Touareg

    Can you please provide the dimensions of the shim that you make (O.D and I.D), I was thinking I could just add shims on the pinion shaft ahead of the crush sleeve and use my original part with minimum new crush. In Drag racing, we used a solid sleeve (no crush) and added shims as required to get the gear alignment and preload right. What I propose is a similar configuration.


  9. topline
    Thanks Mark.

    I'm in the process of trying to fit a rated recovery point to the front of the Touareg. Once done, I will need to see if your plates will still fit.
    What is the latest you need the order and payment?
  10. topline
    Hi Mark

    I have a 2017 v8 tdi and would really love to your guards. Any chance of you advising total cost including postage before committing?
    Unable to send PM yet as post count too low.

    Brian Mitchell
    26 Salamander St
    Dianella 6059
    Western Australia
    topline at iinet dot net dot au

  About Me

  • About dragline1570
    Vehicle Model
    2006 V10 TDI
    Second Vehicle Model
    VW 2
    Maitland Australia
    fitter/ Engine Reconditioner


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  • Last Activity: 13 Hours Ago
  • Join Date: 05-02-2011
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