Removing and installing tunnel cross member: Audi A8 D3

🧭 Before you start

Remove the intake hose, raise the car and disconnect the front exhaust, heat shields, noise insulation and propshaft. Support the engine cross member and subframe, remove the rear subframe bolts and supports, and support the gearbox on a bolt in its mounting hole. Mark and unbolt the tunnel cross member, lower the assembly and remove it. Refit to the marks, align the mountings stress-free and reconnect propshaft, exhaust and subframe.

Fits: Audi A8 D3 (4E, 2002–2010)

Don't miss

• Never support the gearbox on the ATF cooler, gear oil cooler or oil pan.
• Mark the cross member position on the body before removal and refit to those marks.
• Watch the whole engine compartment while lowering so nothing gets crushed or stretched.
• Hand-tighten gearbox mounting bolts first, then tighten once alignment is stress-free.

Written for this job from the workshop steps below · TorqFix editorial.

📋 Procedure

1. Remove intake hose between air cleaner and throttle valve unit.
2. Raise vehicle.
3. Remove cross member (A) below exhaust system.
4. Disconnect front exhaust pipes and catalytic converter from rear section of exhaust system (arrows) and tie up to the side.
5. Remove heat shield (B).

6. Detach air duct (1) from gearbox.
7. Remove noise insulation (2) below engine/gearbox.
8. Remove heat shield (3) for propshaft.
9. Unbolt propshaft (4) from gearbox and tie up or support.
10. Detach heat shield (5) above propshaft and push to rear.
11. ⚠ When performing the steps below, please note the following:Do not support the gearbox on the ATF cooler or gear oil cooler - risk of damage. — Support engine cross member and subframe using engine and gearbox jackV.A.G 1383 A as illustrated.
12. Remove bolts (1) and (2) at rear of subframe on both sides of vehicle 40.
13. Remove supports for subframe (A).
14. ⚠ When performing the steps below, please note the following:Do not support the gearbox under the oil pan - risk of damage. — Insert a bolt M12x100 (item 1) with attached nut (2) into the mounting hole behind the oil pan on the gearbox.
15. Apply lifting column of engine and gearbox jackV.A.G 1383 A to bolt head as illustrated and raise gearbox slightly.
16. Remove bracket for noise insulation below ATF cooler.
17. If fitted, detach bracket for electrical connectors (1) and (2) for lambda probes from tunnel cross member (arrows).
18. Mark installation position of tunnel cross member for gearbox on body.
19. Remove bolts securing gearbox mountings (left (1) and right (2)) to tunnel cross member.
20. Unbolt tunnel cross member for gearbox from body (arrows).
21. Place tunnel cross member on front exhaust pipes.
22. Carefully lower engine and gearbox assembly at rear using engine and gearbox jackV.A.G 1383 A.
23. It is important to watch all parts of the engine compartment to prevent damage.
24. Remove tunnel cross member.
25. Hand-tighten bolts (1) and (2) securing gearbox mounting to tunnel cross member.
26. Raise gearbox and bolt tunnel cross member to body (arrows). [Note: Check the pen markings.]
27. Bolt gearbox mounting to tunnel cross member (1) and (2) (ensure stress-free alignment).
28. Bolt propshaft to gearbox flange Rear final drive 01R39 or Rear final drive 0AR39.
29. Reconnect front exhaust pipes to rear exhaust system 26.
30. Install bolts (1) and (2) at rear of subframe with supports (A). Tightening torques 40

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