Removing and installing end cover: Audi A8 D3 4.2 (BYH, CNDA)

🧭 Before you start

Fits: Audi A8 D3 (4E, 2002–2010)

• Renewed: bolts, gaskets

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• The flexible pipe connection (de-coupling element) on the front exhaust pipe must not be bent more than 10° – otherwise it can be damaged.
• (Item 2) can be disregarded.
• Fit new bolts when installing.
• If any dowel sleeves were removed from gearbox housing or cover, these must be re-fitted in same places.
• The gaskets can be made of metal or paper. The new gasket must be made of the same material as the old one Electronic parts catalogue.Make sure dowel sleeves are correctly seated.

🔧 Engine codes this applies to

📐 1 workshop diagram for BYH

Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.

📋 Procedure

1. ⚠ Do not run engine or tow vehicle with end cover removed or when there is no ATF in the gearbox. — If applicable, activate jacking mode when raising the vehicle Running gear, front-wheel drive and four-wheel drive43Adaptive air suspension.
2. Raise vehicle.
3. Drain off ATF .
4. Remove front cross member (arrows).
5. Unscrew nuts (arrows) on brackets for front exhaust pipes (left and right). [Note: The flexible pipe connection (de-coupling element) on the front exhaust pipe must not be bent more than 10° – otherwise it can be damaged.]

6. Loosen clamps (1) and (2) ...
7. ... and tie up front left and front right exhaust pipes onto body (arrows).
8. Unscrew bolts (arrows) and remove tunnel cross member.
9. Position engine and gearbox jackV.A.G 1383 A with gearbox support T10337 underneath gearbox, as shown in illustration, and support gearbox.
10. Use engine and gearbox jack to lift gearbox up slightly.
11. First remove bolts (2) and (3) and then subframe securing bolts (1) and (4).
12. Using engine and gearbox jackV.A.G 1383 A, lower gearbox far enough to be able to access selector lever cable at selector shaft lever at top of gearbox.
13. Remove bolts (3) at support bracket for selector lever cable.
14. Use removal lever80-200 to prise ball head (1) on selector lever cable off selector shaft lever (arrow). [Note: (Item 2) can be disregarded.]
15. Release electrical connector (arrow) and detach from gearbox.
16. Remove bolts (arrows) and take off end cover. [Note: Fit new bolts when installing.] [Note: Renew gaskets and seals.]
17. Slide new twin-lip oil seal (A) onto connector of gearbox control unit J217, with twin-lips facing outwards.
18. Clean sealing surfaces on gearbox housing and end cover.
19. If any dowel sleeves were removed from gearbox housing or cover, these must be re-fitted in same places.
20. Fit a new gasket (A) for end cover. [Note: The gaskets can be made of metal or paper. The new gasket must be made of the same material as the old one Electronic parts catalogue.Make sure dowel sleeves are correctly seated.]
21. Fit end cover and make sure that gasket does not move out of position.
22. Fit new bolts (arrows): tighten in diagonal sequence finger-tight to start with and then tighten to specified torque (see table). [Note: Fit new bolts when installing.]
23. Carefully check installation position of twin-lip oil seal (A): It must be flush (twin-lips must not fold over).
24. Push selector shaft lever into position "“D”". [Note: In order to securely set position "“D”" on selector shaft lever move the selector shaft lever on gearbox forwards as far as it will go, into position "“P”". Then shift it three positions to the back (opposite to direction of travel).]
25. Install selector lever cable and support bracket . [Note: Do not bend or kink the selector lever cable.Take care not to bend selector shaft lever when pressing on cable; support lever if necessary, as otherwise selector mechanism can no longer be adjusted accurately.Before installing, lightly lubricate ball socket on selector lever cable with polycarbamide greaseG 052 142 A2.]
26. Install subframe Running gear, front-wheel drive and four-wheel drive40.
27. Adjust selector lever cable .
28. Install exhaust system and perform stress-free alignment 26.
29. Deactivate jacking mode Running gear, front-wheel drive and four-wheel drive43Adaptive air suspension.
30. Fill up with fresh ATF .

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