Visual repair of gearbox 097 (Audi A6 C4)

Table of contents: Technical characteristics of AEL ↓ Technical specifications of CBU ↓ Automatic transmission cooling… ↓ Automatic transmission 097 –… ↓ Valve block ↓ Mechanical valve ↓ Oil filter installation position ↓ Parking gear lock ↓ Differential (automatic transmission) ↓ Drive gear ↓ Pinion gear ↓ Differential ↓

Technical characteristics of AEL

Transmission:
Code designation	AEL
Automatic transmission	097
Torque converter:
Code designation	LCCA
Valve block:
Code designation	LAA
Number of spline rings	int.	ext.
– coupling K1	5	4
– coupling K2	5	5
– coupling K3	5	4
– brake B1	6	6
– brake B2	6	5
Engine	Volume 2.3 liters
Final drive ratio	3.70
Gear ratio:
- 1st gear	2.71
- 2nd gear	1.55
- 3rd gear	1.00
- 4th gear	0.68
- reverse gear	2.11
Automatic transmission fluid cooling radiator	installed in the engine radiator

Technical specifications of CBU

Transmission:
Code designation	CBU
Automatic transmission	097
Torque converter:
Code designation	LBCA
Valve block:
Code designation	LAC
Number of spline rings	int.	ext.
– coupling K1	5	4
– coupling K2	5	5
– coupling K3	5	4
– brake B1	6	6
– brake B2	6	7
Engine	Volume 2.3 liters
Final drive ratio	3.70
Gear ratio:
- 1st gear	2.71
- 2nd gear	1.55
- 3rd gear	1.00
- 4th gear	0.68
- reverse gear	2.11
Automatic transmission fluid cooling radiator	installed in the engine radiator

The automatic transmission fluid cooling radiator is installed in the engine radiator

Automatic transmission cooling mechanism

1. Feed hose
2. Bolt, 10 Nm
3. Sealing ring
4. Nut, tightening torque 60 Nm
5. Washer
6. Gearbox housing
7. Automatic transmission coolant filter
8. Dipstick for measuring the level of automatic transmission coolant
9. Radiator - with installed automatic transmission coolant radiator
10. Washer
11. Return line of the automatic transmission coolant radiator
12. Washer
13. Banjo bolt, 40 Nm
14. Clamp
15. Washer
16. Bolt, 10 Nm
17. Banjo bolt, 30 Nm
18. Bolt, 10 Nm
19. Temperature switch, 15 Nm
20. Washer
21. Automatic transmission fluid supply pipe
22. Banjo bolt, 30 Nm - with hole for temperature switch
23. Washer
24. Automatic transmission radiator coolant return pipe
25. Banjo bolt, 40 Nm
26. Sealing ring
27. Automatic transmission coolant radiator feed line
28. Washer

Warning: Tightening torque for fastening the supply hose 1 to the oil pan: 80 Nm

Warning: Always replace O-rings 3, 26.

Warning: Always replace washers 5, 10, 12, 20, 23, 28.

Warning: The automatic transmission coolant filter 7 can be replaced without removing the engine

Warning: Tightening torque of the return pipe of the automatic transmission coolant radiator return line: 40 N·m

Warning: Tightening torque for fastening the 21 automatic transmission fluid feed pipe to the feed line: 40 Nm

Warning: Tightening torque of the coolant return pipe 24 of the automatic transmission radiator to the return pipe: 40 Nm

Warning: Tightening torque of the fastening of the feed pipe of the coolant radiator pipe 27 automatic transmission: 40 N·m

Removal

1. Disconnect the negative battery cable.

2. Disconnect the speedometer connection connector.

3. Disconnect the temperature switch connection connector.

4. Remove the upper engine and gearbox mounting bolts.

5. Disconnect the oxygen sensor connection connector.

6. Disconnect the transmission ground wire.

7. Install the engine mount.

8. Remove the lower engine shield and mounts.

9. Remove the exhaust pipe.

10. Disconnect the axle shafts from the gearbox.

11. Remove the starter bolts.

12. Place the starter on its side and secure it with wire.

13. Remove the torque converter mounting nuts (3 pieces).

14. Remove the heat shield of the multifunction switch.

14. Remove the heat shield of the multifunction switch.

15. Disconnect connection connectors 1, 2 and 3.

16. Remove the wire clamp from the gearbox.

17. Disconnect the automatic transmission coolant pipes.

18. Seal the hoses using plugs, part number 357 853 586 B.

19. Seal the tubes with rubber caps, part 055 121 324.

Disclaimer: Part numbers are provided for reference purposes only.

20. Place a support or suitable lift under the transmission.

21. Remove the gearbox mounts.

22. Remove the shift lever clamp.

23. Disconnect the cable.

24. Remove the lower engine/transmission mounting bolts.

25. Move the axle shafts back.

26. Disconnect the gearbox from the engine.

27. Carefully lower the gearbox.

28. Support the torque converter to prevent it from falling.

Installation

1. Installation is carried out in the reverse order of removal.

2. Make sure the guide bushings are positioned accurately during installation.

3. Check the gear shift cable adjustment.

4. Adjust the cable if necessary.

Tightening torque

Fastening the axle shafts to the drive flanges	80 Nm
Torque converter mounting bolts	60 Nm
Gearbox to engine mounting bolts (4-cylinder)	55 Nm
Gearbox to engine mounting bolts (5-cylinder)	see table Tightening torques (5-cylinder engines)
Fastening the gearbox bracket to the gearbox	40 Nm
Fastening the gearbox to the body	110 Nm

Automatic transmission 097 – housing, gears, shafts/ Automatic transmission mechanism

1. Lid
2. Bolt, 30 Nm - for small drive shaft
3. Washer
4. Washer - for planetary gear carrier
5. Gearbox housing
6. Washer
7. Thrust needle bearing
8. Washer
9. Sealing ring
10. Planetary gear carrier
11. Washer - for reverse gear brake (B1)
12. Internal spline ring
13. External spline ring
14. Pressure ring
15. Ring spring
16. One-way clutch - with piston B1
17. Retaining ring - for one-way coupling
18. Oil deflector
19. Retaining ring - for mounting rim
20. Central gear, small
21. Washer
22. Thrust needle bearing
23. Central gear, large
24. Washer
25. Thrust needle bearing
26. Drive shaft, large
27. Thrust needle bearing
28. Needle bearing
29. Drive shaft, small
30. Thrust needle bearing
31. Washer
32. 3rd/4th gear clutch (K3) - with pump shaft
33. Washer
34. Thrust needle bearing
35. Washer
36. Clutch 1st - 3rd gear (K1) - with turbine shaft
37. Washer - for adjusting the free travel of the K1 and K2 clutches (if necessary, a second washer is installed)
38. Washer - for adjusting the free travel of the K1 and K2 clutches (if necessary, a second washer is installed)
39. Reverse clutch (K2)
40. Mounting rim
41. External spline ring
42. Internal spline ring
43. Spring cap
44. External spline ring
45. Spring
46. Spring cap
47. External spline ring
48. Spring washer, concave
49. Gasket
50. Sealing ring
51. Automatic transmission coolant pump
52. Bolt, 10 Nm

Warning: Remove cover 1 using a screwdriver and install using a 40–20 bushing.

Warning: The tongues of washer 6 face the thrust needle bearing.

Warning: Always replace the sealing ring 9, installed on the planetary carrier

Caution: When installing, lightly grease the washers and needle bearing, install the washers and needle bearing on the planet carrier, and then install the planet rings

Warning: Before installing new 12 spline inner rings, soak them in automatic transmission fluid for 15 minutes.

Warning: The flat side of the pressure ring 14 faces the rings.

Warning: The curved side of the ring spring 15 faces the one-way clutch.

Warning: After installing the retaining ring 17, install the oil deflector 18.

Warning: Oil deflector 18 is installed in the groove of the gearbox housing (near the automatic transmission fluid vent), install the reflector after installing the one-way clutch and before installing the retaining ring.

Warning: Before installing the retaining ring 19, check that the one-way clutch and oil deflector are installed.

Warning: Central gears 20, 23 are installed on the planetary gear carrier.

Caution: Install washer 21 with the rounded side facing the small central gear.

Warning: Washer 24 is installed with the beveled side into the large central gear.

Warning: Drive shafts 26, 29 are installed on the planetary gear carrier.

Warning: The 30 thrust needle bearing faces the small drive shaft. The washer may be installed on the needle bearing.

Warning: The tongues of washer 31 face the thrust needle bearing, the washer can be installed on the needle bearing

Warning: The tongues of washer 33 face the thrust needle bearing.

Warning: The mounting rim 40 is installed so that the wedges of the one-way clutch enter the groove.

Warning: Always install the 41 mm thick outer spline ring.

Warning: Before installing new 42 mm internal spline rings, soak them in ATF for 15 minutes.

Warning: Remove all three spring caps 43, install after installing the first outer spline ring.

Warning: Always install the 44 mm thick outer spline ring.

Warning: Remove all three 45 springs, install after installing all outer spline rings.

Warning: Remove all three spring caps 46, install before installing the last outer spline ring.

Warning: Always replace gasket 49.

Warning: Always replace the sealing ring 50, installed on the automatic transmission coolant pump.

Pin Location

Warning: Before installing the motor, check that the pins are in place.

For some gearboxes installed on a 5-cylinder engine, it is necessary to install a deflection sleeve (detail 012 301 153).

When installing a new engine, check for the presence of a bushing on the crankshaft. This bushing should be installed first, before installing the drive plate.

Part numbers are provided for reference purposes only. Contact your dealer for the latest information.

Tightening torques (5-cylinder engines)

Position	Bolt size	Quantity	Tightening torque (Nm)
1	M12x67	1	65
2	M12x80	3	65
3	M12x90	1	65
4	M12x100	1	65
5	M12x120	1	65
6	M12x50	1	45
7	M12x38	1	45
8	M12x40	2	25
Positions A and B – centering bushings

Valve block

1. Oil pan
2. Bolt, 10 Nm
3. Gasket
4. Spacer
5. Oil filter
6. Valve block
7. Bolt, 10 Nm
8. Connection connector
9. Sealing ring
10. Plug
11. Sealing ring
12. Sealing ring
13. Mechanical valve transmitting rod
14. Main gear housing
15. Seal
16. Bolt, 5 Nm
17. Bolt, 8 Nm
18. Automatic transmission coolant radiator feed pipe
19. Bolt, 10 Nm

Warning: The valve block can be removed without removing the transmission from the vehicle. Replace the valve block if it is dirty or damaged.

Warning: Do not start the engine or tow the vehicle if the oil pan has been removed or there is no oil in the transmission.

Caution: Before removing oil pan 1, remove the coolant feed pipe.

Warning: Always replace gasket 3, install spacer on gasket.

Warning: Install spacer 4 on the gasket.

Warning: Install oil filter seal 5.

Warning: Connection connector 8 is installed together with a sealing ring.

Warning: Always replace O-rings 9, 11, 12.

Warning: Remove plug 10 before removing/installing the one-way clutch.

Warning: The flanged end of the mechanical valve transmission rod 13 must face the valve.

Warning: Always replace seal 15, installed in the oil filter.

Warning: Tightening torque for fastening the coolant radiator feed pipe 18 automatic transmission to the oil pan: 80 N·m

Identification

The code designation is embossed on a metal plate which must remain attached to the valve block.

Execution order

1. Install the sealing rings onto the plug.

Warning: Before removing/installing the one-way clutch, remove the plug from the crankcase to avoid damaging the plug and sealing ring.

2. Install the plug so that the rim is in the groove on the crankcase.

Mechanical valve

Installation

1. Move the gear shift lever to position P.

2. Install the mechanical valve all the way into the valve block. The transmitting rod A is indicated by the arrow.

3. Tighten limit screw B to 4 Nm

Warning: The lever C of the mechanical valve must be pressed against the limit screw B during installation. When tightening the screw B of the lever C of the mechanical valve, hold the lever by pressing it in the direction of the arrow.

Oil filter installation position

Parking gear lock

1. Bolt, 10 Nm
2. Plug
3. Sealing ring
4. Parking brake lock latch
5. Parking gear
6. Parking gear lock latch pin
7. Return spring
8. Lock - for multifunctional switch
9. Bolt, 10 Nm
10. Multi-function switch (F125)
11. Sealing ring
12. Cap
13. Main gear housing
14. Sealing ring
15. Speed sensor
16. Bolt, 10 Nm.
17. Gear shift shaft lever
18. Bolt, 10 Nm
19. Bushing
20. Sealing ring
21. Gear shift shaft
22. Locking washer
23. Bolt, 10 Nm
24. Mechanical valve lever
25. Bolt, 4 Nm
26. Locking spring
27. Bolt, 10 Nm
28. Lever

Warning: Always replace O-rings 3, 11, 14, 20.

Warning: Parking brake lock latch 4 is installed together with the return spring, align with the parking gear pinion.

Caution: The rounded side of the parking gear pinion 5 faces the drive gear cover.

Caution: Install the parking gear lock latch pin 6 using a drift.

Warning: Remove/install bushing 19 using a mandrel.

Warning: O-ring 20 is installed in the groove of the gearshift shaft.

Warning: Before removing the gear shift shaft 21, remove the multi-function switch and locking spring, always install together with the lever.

Differential (automatic transmission)

Warning: If you drop the speedometer drive during assembly, it may affect the accuracy of the speedometer readings in the future.

Warning: If you drop the speedometer drive during assembly, it may affect the accuracy of the…

1. Bolt, 25 Nm
2. Left axle shaft flange
3. Axle shaft flange seal
4. Bolt, 25 Nm
5. Automatic transmission fluid filler plug
6. Speedometer drive
7. Sealing ring
8. Main gear cover
9. Seal
10. Axle shaft flange retaining ring
11. Half shaft flange
12. Sealing ring
13. Seal
14. Needle bearing
15. Gearbox housing
16. Gasket
17. Axle shaft ventilation cover
18. Bolt, 10 Nm
19. Differential
20. Pulse ring - for electronic speedometer

Warning: Do not use household detergents to avoid damaging the washer pump.

Warning: Always replace O-rings 7, 12.

Warning: When replacing final drive cover 8, adjust the ring gear installation.

Warning: Always replace oil seal 9.

Warning: Remove oil seal 13 using lever VW681.

Drive gear

1. Rubber cover
2. Tension bolt, 250 Nm
3. Spherical washer
4. Washer
5. Inner race of tapered roller bearing
6. Outer race of tapered roller bearing
7. Gearbox housing
8. Thrust bearing
9. Outer race of tapered roller bearing
10. Inner race of tapered roller bearing
11. Drive gear

Warning: Remove rubber cover 1 with a screwdriver and install with a 40-20 bushing.

Warning: When removing/installing bolt 2, engage the parking gear.

Caution: The convex side of the spherical washer 3 faces the tension bolt.

Caution: Tapered roller bearing inner race 5: Install so that the tongues fit into the groove of the other tapered roller bearing inner race. After determining the required shim thickness, install the race onto the pinion gear after applying a coat of AMV 185 10001 sealant.

Warning: Tapered roller bearing outer race 6: Remove with a suitable drift, install with a 30-20 thrust block, apply a layer of AMV 185 10001 sealant.

Warning: The flat side of the thrust bearing 8 faces the drive shaft, install the tension bolt on the drive gear before installation.

Warning: Tapered roller bearing outer race 9: Remove using a suitable drift, install using a thrust block, apply a coat of AMV 185 10001 sealant.

Pinion gear

1. Gearbox housing
2. The drive gear is paired with the ring gear
3. Inner race of tapered roller bearing
4. Outer race of tapered roller bearing
5. Washer S3
6. Drive gear shaft sleeve
7. Pinion shaft seal
8. Rubber cover
9. Hexagonal nut
10. Inner race of tapered roller bearing
11. Outer race of tapered roller bearing
12. Bolt, 25 Nm
13. Drive gear cover
14. Sealing ring
15. Spacer sleeve
16. Washer S4
17. Drive pinion
18. Parking gear lock gear

Warning: Do not use household detergents to avoid damaging the washer pump.

Warning: Pinion 2 is paired with the ring gear and must be replaced together.

Caution: Tapered roller bearing outer race 4: Remove using a drift.

Warning: Pinion shaft sleeve 6: Remove together with the inner race of the tapered roller bearing.

Warning: Pinion shaft seal 7: Always replace, remove with a screwdriver.

Warning: Rubber cover 8: Remove with a screwdriver.

Caution: Tapered roller bearing outer race 11: Remove using a drift.

Warning: Always replace O-ring 14.

Warning: Spacer sleeve 15: The wider contact surface faces the drive gear.

Warning: Pinion drive 17: Higher edge faces parking gear lock latch.

Warning: Parking gear lock pinion 18: Rounded side faces drive pinion.

Differential

1. Differential cover
2. Impulse wheel
3. Washer S1
4. Outer race of tapered roller bearing
5. Bolt, 90 Nm
6. Inner race of tapered roller bearing
7. Differential box
8. Toothed crown - paired with the leading pinion
9. Inner race of tapered roller bearing
10. Outer race of tapered roller bearing
11. Washer S2
12. Gearbox housing
13. Satellites
14. Thrust washer
15. Half-axle gears
16. Output shaft
17. Retaining ring
18. Axis of satellites
19. Half shaft flange nut

Warning: Before installing the inner race of tapered roller bearing 9, heat it to 100°C.

Warning: When installing the satellite axle, be careful not to damage the thrust washer.

Caution: Tapered roller bearing outer race 4: Remove using a drift.

Warning: Differential box 7: Adjust after replacing the ring gear.

Warning: The toothed ring 8 is paired with the drive pinion, replaced together, after replacement, adjust the installation of the toothed ring and drive pinion. To remove, remove from the differential box using a mandrel. Before installation, heat to 100°C and install the centering pins.