2020051-4

SB-10043931-6390
Technical Service Bulletin
57 Door cannot be opened from outside handle in cold weather
57 12 63 2020051/4 March 15, 2012. Supersedes Technical Service Bulletin Group 57 number 11 – 44 dated
February 16, 2011 for reasons listed below.
Model(s)
Year
VIN Range
Vehicle-Specific Equipment
Audi Q7
2007 – 2010
All
Not Applicable
Condition
REVISION HISTORY
Revision
Date
Purpose
4
-
Revised header data
Revised Warranty
3
2/16/2011
Revised Customer codes
Revised Warranty
2
10/27/2009
Revised Technical Background
Revised Production Solution
Revised Service
Revised Required Parts and Tools
1
3/27/2009
Original publication
Door cannot be opened or closed from outside the vehicle in cold weather.
Technical Background
A plastic burr on the bearing bracket can cut the outer
sheathing material of the Bowden cable. As a result, water can
enter through the outside door handle and into the sheathing of
the Bowden cable. In extremely cold weather, it is possible for
the Bowden cable to freeze. In this condition, the door-opening
function of the outside door handle may intermittently or
consistently be inoperative until the vehicle is allowed to warm.
When the vehicle is entered through a different door and
moved to a location where it can be warmed, the outside door
handle becomes operative.
Figure 1. Cut in Bowden cable.
The functionality of the inside door handle is not affected by this condition.
© 2012 Audi of America, Inc.
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All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval
system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior
expressed written permission of the publisher.
Technical Service Bulletin
Production Solution
Remove all plastic burrs from the bearing bracket and apply a protective fabric cover over the cable to prevent the
cable from being cut.
Service
1. Obtain a new exterior door handle
bearing bracket assembly, which
includes the Bowden cable.
The part number revision has not
changed for the reworked parts.
Improved parts will eventually be
introduced with a new part
number revision.
Figure 2. Bowden cable (1), and door handle mounting
bracket (2).
2. Determine whether the replacement part is reworked. The reworked parts are indicated by
two green dots near the cable attachment point on the bearing bracket.
© 2012 Audi of America, Inc.
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All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval
system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior
expressed written permission of the publisher.
Technical Service Bulletin
• If two green dots are present on the
replacement parts, then proceed to step 3.
Figure 3. Bearing bracket with two green
dots.
• If no green dots are present on the replacement part, then the following two steps must be
performed:
a. Check the bearing bracket for any sharp
plastic burrs or sharp edges. Round the
edges and remove any burrs with a
small metal file.
Figure 4. Location on bearing bracket to
check for burrs.
b. Apply a protective fabric strip around the
Bowden cable where it touches the
bearing bracket.
Figure 5. Location to apply Bowden cable
fabric (red).
© 2012 Audi of America, Inc.
Page 3 of 5
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval
system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior
expressed written permission of the publisher.
Technical Service Bulletin
3. Replace the exterior door handle bearing bracket assembly, including the Bowden cable.
Tip: It is not necessary to replace the door lock mechanism, nor is it necessary to replace the interior door
handle Bowden cable.
Warranty
Claim Type:
Use applicable claim type. If vehicle is outside any warranty, this Technical Service Bulletin
is informational only.
Service Number:
5745
Damage Code:
0017
Labor Operations:
Front door handle bearing bracket remove +
reinstall (one side)
5711 1955
20 TU
Front door panel remove + reinstall (one side)
7059 1900
40 TU
Front door handle bearing bracket remove +
reinstall (both sides)
5711 2055
30 TU
Front door panel remove + reinstall (both sides)
7059 2000
70 TU
Rework bearing bracket assembly (if necessary)
5745 9999
20 TU
Rear door handle bearing bracket remove +
reinstall (one side)
5811 1955
20 TU
Rear door panel remove + reinstall (one side)
7073 1900
40 TU
Door handle bearing bracket remove + reinstall
(both rear doors)
5811 2055
30 TU
Rear door panel remove + reinstall (both sides)
7073 2000
70 TU
GFF
No allowance
0 TU
Road test prior to service procedure
No allowance
0 TU
Road test after service procedure
No allowance
0 TU
Diagnostic Time:
Technical diagnosis at dealer’s discretion
(Refer to Section 2.2.1.2 and Audi Warranty Online for DADP allowance details)
Claim Comment:
As per TSB #2020051/4
All warranty claims submitted for payment must be in accordance with the Audi Warranty Policies and Procedures
Manual. Claims are subject to review or audit by Audi Warranty.
© 2012 Audi of America, Inc.
Page 4 of 5
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval
system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior
expressed written permission of the publisher.
Technical Service Bulletin
Required Parts and Tools
Part Number
Part Description
Quantity
See ETKA
Bow
1
D004 350 A2
Textile adhesive tape
1
Not applicable
Metal file
1
Additional Information
All parts and service references provided in this TSB are subject to change and/or removal. Always check with
your Parts Department and service manuals for the latest information.
© 2012 Audi of America, Inc.
Page 5 of 5
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval
system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior
expressed written permission of the publisher.