A3920352051558_4

39 Four-wheel drive malfunction message, DTC C05ED00 is stored in the all-wheel drive control module
39 20 35 2051558/4 August 21, 2020. Supersedes Technical Service Bulletin Group 39 number 20-32 dated June
17, 2020 for reasons listed below.
Model(s)
Year
VIN Range
Vehicle-Specific Equipment
Q5, SQ5
2018
All
Quattro Ultra
Q5, SQ5
2019
000001 - 124125
Quattro Ultra
A6, A7, S6,
and S7
2018 - 2019
All
Quattro Ultra
A6, A7, S6,
and S7
2020
000001 - 008938
Quattro Ultra
A4, A4
allroad, and
S4
2018
All
Quattro Ultra
A000001 - A021502
A4, A4
allroad, and
S4
2019
A5, A5
Cabriolet.
A5
Sportback,
S5, S5
Cabriolet,
and S5
Sportback
2018
Or
Quattro Ultra
N000001 - N001666
A5, A5
Cabriolet.
A5
Sportback,
S5, S5
Cabriolet,
and S5
Sportback
All
Quattro Ultra
A000001 –A073698
2019
Or
Quattro Ultra
N000001 - 010733
Condition
REVISION HISTORY
Revision
Date
Purpose
4
-
Revised Service (Updated instructions to reuse springs)
Revised Required Parts and Tools (Updated Vise part number)
Page 1 of 16
© 2020 Audi of America, Inc.
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.
3
06/17/2020
Revised Technical Background (Updated information and added photo)
Revised Service (Replacing shift fork inside differential)
Revised Warranty (Labor operations changed to include the new repair)
Revised Required Parts and Tools (Updated tools table)
2
03/20/2020
Revised Warranty (Updated Labor Operations)
Customer states:
 The message "four-wheel drive malfunction" is sporadically shown in the instrument cluster.
Workshop findings:
The following DTC is logged in the all-wheel drive control module, J492 (address word 0022):
 DTC C05ED00 (4WD/AWD Clutch "B" Stuck Engaged) with symptom code 29725.
Technical Background
Quattro Ultra shift fork inside the rear differential is
worn/faulty (Figure 1).
Figure 1. Worn/faulty shift fork.
Production Solution
Improved material in production
Page 2 of 16
© 2020 Audi of America, Inc.
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.
Service
Proceed as follows:
Complete the ODIS test plan for the DTC C05ED00 (4WD/AWD Clutch "B" Stuck Engaged) completely
according to Guided Fault Finding to rule out other reasons for the restricted function and to avoid an
unnecessary parts replacement:
 If the result of the test plan leads to a repair, follow the Guided Fault Finding repair advice and this TSB does
not apply.
 If the result of the test plan finds no defect, perform a short test drive. If the same DTC returns after the test
drive with the same symptom, the shift fork inside the rear differential is at fault and must be replaced.
Perform the repair as follows. Do not replace the complete differential.
1.
Drain the oil of the rear differential according to the repair manual.
2.
Remove the rear differential per the repair manual.
Tip: Although there are instructions available in the Elsa repair manual to perform this repair, the tools
utilized in Elsa have never been required tools. Our records indicate that few dealers have procured them as a
result. The repair shown in this TSB uses tools that are minimum required tools and one tool that will be auto
shipped to Audi dealers shortly. If you are missing a tool for this repair, please order it and continue with the
repair.
At the time of publishing this TSB, we have enough tools in stock to handle these repairs/orders. If the web site
shows no availability of a tool that you require, please call SBS directly at 1-800-892-9650 as they may have
stock that is not showing on the site.
3.
Place the differential on a workbench and remove the All-Wheel Drive Clutch Actuator 2 -V623- according
to the repair manual.
Page 3 of 16
© 2020 Audi of America, Inc.
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.
4.
Loosen the case bolts -1 to 9- and separate the
housing halves saving the bolts as they will be
reused for reassembly (Figure 2). Use care to
not damage the sealing surfaces.
Figure 2. Case bolts.
5.
Mount the side carrier as shown below (Figure
3) to the VAS6095 using T40206, T40206/1A,
one long slotted arm from the VAS6095, 3350/2
(Figure 4 and Figure 5), three M10 flat washers
2mm thick each (Figure 5), one M10 x 1.5 x70
bolt (Figure 4 and Figure 5), and one M12 x 1.5
x 38 bolt (Figure 4).
Figure 3. Mounted side carrier.
Page 4 of 16
© 2020 Audi of America, Inc.
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.
Figure 4. Mounting detail.
5a.
Figure 5. Mounting.
The passenger side differential mount attaches to the T40206/1A at hole #6 and the long slotted arm of the
VAS6095 attaches to threaded hole 5A using one of the M12 x 1.75 x 40 bolts from the VAS6095
engine/transmission stand (Figure 7). Alternately the long slotted arm of the VAS6095 can attach to
threaded hole 5B with any M12 bolt and a nut (bolt must be 50mm or longer).
Figure 6. Mounting.
Figure 7. Mounting.
Page 5 of 16
© 2020 Audi of America, Inc.
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.
6.
Pull out the gear carrier (Figure 8, position 3)
using the VAS 251001 with VAS 251 001/2
(Figure 8, position 1) and thrust piece 30 – 555
(Figure 8, position 2).
Alternate puller tool T10040 with T10040/2. This
tool is harder to get jaws in the access holes but
it will work.
Alternate thrust pieces can also be used and a
test repair was performed not using a thrust
piece. If no thrust piece is used you may
damage the end of the puller or the shaft if too
much force is applied.
7.
Figure 8. Puller arrangement.
Remove the gear carrier (Figure 9, position1
and Figure 10). During this step, guide the shift
fork out of the clutch module (engagement
collar), then remove the shim (Figure 9, position
2).
Figure 9. Gear carrier and shim removal.
Page 6 of 16
© 2020 Audi of America, Inc.
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.
Figure 10. Gear carrier removal.
8.
Remove the springs and save them for
reinstallation (Figure 11, position 1).
Remove the roller sleeves (Figure 11, position
2).
Figure 11. Shift fork assembly.
Page 7 of 16
© 2020 Audi of America, Inc.
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.
9.
Install an M8 flange nut (Figure 12, position 3)
onto the T10172/9 (Figure 12, position 4).
Tension the gear carrier in the vise as shown
(Figure 12, position 1) using the plastic or brass
soft jaws (Figure 12, 2). You may need a 2 nd
technician to assist you in holding the carrier.
Position the sleeve provided in the repair kit Part
# 0B0 598 082 (Figure 12, position 6) between
the shift fork (Figure 12, position 8).
Press out the bearing pin (Figure 12, position 5)
until the thrust piece stops (Figure 12, position
4).
Figure 12. Pin removal.
The bearing pin (Figure 12, position 5) remains
in the shift fork (Figure 12, position 8) together
with the sleeve (Figure 12, position 6).
Repeat the procedure on the other side.
10.
Insert the pins (Figure 13, position 1) into the
holes of the gear carrier.
The pins have to be easy to move in and out of
the holes
Figure 13. Pin checking.
Page 8 of 16
© 2020 Audi of America, Inc.
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.
11.
Insert the new shift fork from the repair kit
(Figure 14, position 2) into the gear carrier, and
in doing so pay attention to the right installation
position.
Flap the latch (Figure 14, position 1) outward for
installation.
Insert the shift fork (Figure 14, position 2) into
the recess of the gear carrier -arrow-.
Partially insert the new pins provided in the
repair kit (Figure 14, position 3), to secure the
shift fork for the next step (Figure 14, position
2).
Figure 14. Installing a new shift fork.
12.
Pressing in the bearing pin with a vise using the
plastic or brass soft jaws:
 Tension the gear carrier (Figure 15, position
2) and pin -5- as shown into the vise (Figure
15, position 4).
 Push in the pin (Figure 15, position 5) so far
that it is flush with the inner side of the shift
fork (Figure 15, position 1).
 Repeat the procedure on the other side.
 Check if the shift fork (Figure 15, position 1)
can be swiveled with ease.
Figure 15. Pressing a pin with a vise.
Page 9 of 16
© 2020 Audi of America, Inc.
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.
12a Alternately, we realize not all shop vises will
.
accept the procedure above. If your vise works
you can proceed to step #13.
As a workable option, the minimum required tool
582277 Stud Remover can be used in place of a
vise with T10172/9 with an M8 flange nut
threaded on the T10172/9 (Figure 16).
Figure 16. Stud remover 582277.
12b Insert the T10172/9 with the M8 flange nut as
shown and the collared nut provides a solid
surface to press the pin against (Figure 17).
Figure 17. T10172/9 installed in 582277.
Page 10 of 16
© 2020 Audi of America, Inc.
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.
12c Set up the 582277 stud remover to press in the
pin (Figure 18). The spindle might “walk” offcenter and if it does loosen the spindle and
center it again and continue pressing. You can
also mount the body of the 582277 stud
remover in a vise to steady it while pressing the
pins. Press in one pin and then repeat on the
opposite side.
Figure 18. Pin pressing with the 582277.
13.
Apply a small amount of assembly grease to the
pins for the bushing and install the new
bushings from the repair kit (Figure 19, position
2).
Reinstall the springs (Figure 19, position 1).
Figure 19. Bushing and spring installation.
14.
Insert the shim (Figure 20, position 3).
If the coupling sleeve (Figure 21, position 3) is easily removed from the shaft, remove it and insert it into
the gear carrier (Figure 21). Pay attention that the sleeves (Figure 21, position 1) engage into the groove of
the coupling sleeve (Figure 21, position 3).
Page 11 of 16
© 2020 Audi of America, Inc.
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.
Insert the gear carrier (Figure 20, position 1) into the housing together with the coupling sleeve. Pay
attention that the shock absorber (Figure 20, position 2), and the centering pin are correctly positioned to
the housing (Figure 20, arrow).
If the coupling sleeve (Figure 21, position 3) is difficult to remove from the shaft you can raise it up the
shaft and install it into the clutch module and install the gear carrier paying attention to the steps above.
Figure 20. Shim and carrier installation.
Figure 21. Detail of coupling installation.
15.
Remove the magnet (Figure 22, position 1),
clean it, and re-insert.
Figure 22. Magnet location.
Page 12 of 16
© 2020 Audi of America, Inc.
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.
16.
Clean any oil and sealant residue off of the
housing halves.
Apply the sealant (D 176 501 A1) onto the
housing halves for the differential as shown
(Figure 23).
Figure 23. Sealant application.
17.
Reassemble the case halves.
Figure 24. Case halves.
Page 13 of 16
© 2020 Audi of America, Inc.
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.
18.
Install and torque the case bolts as follows and
in the sequence shown (Figure 25):
 Install all the way by hand.
 Torque the bolts in sequence to 30 Nm.
 Turn each bolt an additional 45° in
sequence.
Tip: The bolts for the differential case are
reused.
Figure 25. Tightening sequence.
19.
Install the All-Wheel Drive Clutch Actuator 2 -V623- per the repair manual.
20.
Install the differential into the vehicle per the repair manual.
21.
Fill the differential with oil per the repair manual.
22.
Clear faults and test drive to confirm the repair.
Warranty
Claim Type:
 110 up to 48 Months/50,000 Miles.
 G10 for CPO Covered Vehicles – Verify Owner.
 If the vehicle is outside any warranty, this Technical Service Bulletin is informational
only.
Service Number:
3988
Damage Code:
0016
Labor Operations:
AWD final drive assembly remove + reinstall
3988 19XX
See SRT with
associated
operations
Some models have associated labor
operations for remove + reinstall AWD final
drive assembly depending on their equipment
See Elsa
See SRT with
associated
operations
Repair final drive (Replace Shift Fork)
3988 4199
130 TU
Page 14 of 16
© 2020 Audi of America, Inc.
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.
Diagnostic Time:
Claim Comment:
GFF
0150 0000
Time stated on
the diagnostic
protocol (Max 100
TU)
Road test prior to service procedure
0121 0002
10 TU
Road test after service procedure
0121 0004
10 TU
As per TSB #2051558/4
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.
Required Parts and Tools
Always check with your Parts Department and/or ETKA for the latest information and parts bulletins.
Part Number
Part Description
Quantity
See ETKA
Fasteners, Bolts, Nuts, and Screws as needed per the
Repair Manual
See ETKA/ELSA
0B0598082
Repair kit (selector fork)
01
G 060190A2
Axle oil
01
D 176501A1
Sealant
01
M10
Flat washers (2mm thick each)
03
Tool Number
Tool Description
VAS6095
Engine Stand
T40206 with T40206/1
Gearbox Support
3350/2
Bearing Installer
N 10560702 or equivalent
Bolt M10 x 1.5 x 70
N 91041702 or equivalent
Bolt M12 x 1.5 x 38
VAS6095 engine stand
bolt or equivalent
Bolt M12 x 1.75 x 40
Page 15 of 16
© 2020 Audi of America, Inc.
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.
VAS251001 with
VAS251001/2
or
Two Arm Puller
T10040 with T10040/2
T10172/9
Counter hold - Kit (multiple use)
N 91182201 or equivalent
M8 flange nut
30 – 555 or equivalent
Press Piece - Pad
WIL745 or equivalent
Shop Vise
582277
Stud Remover (optional if needed)
VAS6095
Engine Stand
Additional Information
All parts and service references provided in this TSB (2051558) are subject to change and/or removal.
©2020 Audi of America, Inc. 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.
Page 16 of 16
© 2020 Audi of America, Inc.
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.