A5021062062633_1

50 Creaking noises heard when body twists during braking or steering maneuvers
50 21 06 2062633/1 March 19, 2021.
Model(s)
Year
VIN Range
Vehicle-Specific Equipment
A4
2017 - 2022
All
Not Applicable
A4 allroad,
A5, A5
Sportback,
and A5
Cabriolet
2018 - 2022
All
Not Applicable
Condition
Customer states:
 A creaking type noise is heard in the floor area.
 The noise can be generated during strong braking or steering maneuvers where the vehicle body is twisted.
Workshop findings:
 Diagnosis locates the source of the noise from the floor area specifically radiating from the footwell to the area
under the seat.
Technical Background
During a cornering or hard braking
maneuver the longitudinal member
reinforcement plate ‘P’ over the
threaded console ‘T’ can make
contact at point ‘U’ (Figure 1).
Figure 1. Cutaway view of the longitudinal member.
Production Solution
There has been an improvement in the construction of the longitudinal member assembly.
Page 1 of 19
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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
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Service
1.
Duplicate the noise on a test drive preferably with the customer so that the conditions under which this
symptom presents are clearly identified. Also determine from which side of the vehicle the noise originates.
If this noise is duplicated on the test drive confirmation that the source of the noise is from the longitudinal
member and that the repair described in this TSB will be effective can be achieved as follows.
2.
Begin your diagnosis by loosening the front
most bolt on the subframe mounting as
indicated in Figure 2. The bolt only needs to
be loosened several turns but not removed.
Figure 2. Front most bolt on subframe to be loosened.
Note:
As specified in the repair manual, it is necessary to replace all loosened subframe bolts at the conclusion of the
entire repair.
3.
In many cases an audible ‘cracking’ noise
can be heard in the course of loosening and
tightening the subframe bolt (Figure 3).
Figure 3. Loosening the front most subframe bolt.
Page 2 of 19
© 2021 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.
Test drive the vehicle.
 If there is no change or elimination of the noise achieved during this diagnostic step, the repair in this
TSB will not be effective and diagnosis must continue outside the scope of this repair procedure.
 If the noise characteristics do, in fact, change or if the noise is eliminated proceed as follows.
5.
Duplication of this noise is difficult when the
vehicle is cold. If you suspect that the cold is
preventing duplication of this symptom warm
up the longitudinal member/body in the area
of the rear transverse link bolted connection
with a hot air blower set for an outlet temp of
approximately 550°C (1022 °F) (Figure 4).
Figure 4. Warming the area of the body near the rear
transverse link.
6.
Warm the surface to approximately 65 °C
(149°F) (Figure 5).
Figure 5. Surface temperature warmed to 65° C (149°F).
Page 3 of 19
© 2021 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.
7.
Allow the surface temperature to cool to
approximately 30 °C (86°F) then test drive
the vehicle again (Figure 6).
Figure 6. Surface temperature cooled to approximately 30° C
(86°F).
8.
Merely lowering the vehicle from the hoist can immediately elicit the noise symptom after this warming
process.
9.
With the symptom confirmed, remove the
front middle underbody trim ‘B’, front
underbody trim ‘C’ and the underbody trim
‘D’ (Figure 7).
Figure 7. Underbody trim to be removed.
Page 4 of 19
© 2021 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.
10. In order to provide appropriate access to the
affected area inside the longitudinal member
begin by unscrewing the four sheet nut
fasteners ‘F’ for the heat shield from their
studs.
Bend the heat shield slightly away from the
longitudinal member (Figure 8).
Remove grommet ‘E’.
Figure 8. Gaining access to the longitudinal member.
11. Remove grommet ‘H’ from the longitudinal
member (Figure 9).
Figure 9. Remove grommet ‘H’.
Page 5 of 19
© 2021 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.
12. Because bolt ‘G’ was loosened in the
diagnosis process it must be replaced.
Replace bolt ‘G’ using the installation and
tightening procedure in ElsaPro.
Remove the impact protector ‘K’. Pry out clip
‘I’ from the impact protector and remove it
from the longitudinal member (Figures 10 11).
Figure 10. Remove impact protector.
Figure 11. Impact protector removed.
Page 6 of 19
© 2021 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.
13. By shining a flash light through the opening
‘K’ from the now removed impact protector
you can see the upper round hole ‘M’
(Figure 12) in the longitudinal member
reinforcement plate ‘N’ (Figure 13) when
viewed through hole ‘L’ (hole from grommet
‘E’ from Figure 8).
Figure 12. Access for improvised tool.
14. Figure 13 shows the view through hole ‘L’
when illuminated through hole ‘K’ (Figure
12). This is the path through which you will
insert an improvised chisel.
Figure 13. Access hole ‘M’ and access hole in longitudinal
member reinforcement.
Page 7 of 19
© 2021 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.
15. An improvised tool for this modification will
be necessary. Begin fabricating this tool by
obtaining a steel rod 10mm in diameter and
50cm long (Figure 14). Grind the tip of one
end of the rod into a chisel shape. The
length of the grind should be 15mm +/-3mm
on each side as shown in Figure 14.
Figure 14. Ground tip of steel rod.
16. Mount one end of the rod into a vice 11cm
deep with the chisel shape parallel to the
ground (Figure 15).
Figure 15. 50cm long x 10mm steel rod.
Page 8 of 19
© 2021 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.
17. A bend will be created 11cm deep from the
chisel end (Figure 16).
Figure 16. Rod inserted in a vice 11cm from the chisel end.
18. Bend the steel bar at the 11cm apex until a
distance of 43 mm +/- 3 mm is created
between the axis of the longer end of the rod
and the axis of the shorter end of the rod at
its tip (Figure 17).
Figure 17. Bend created 43mm from the axis of the long end
of the steel rod.
Page 9 of 19
© 2021 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.
19. Measure and verify this distance (Figure 18).
Figure 18. Verifying distance of 43mm in the bend.
20. Insert the chisel end of the steel rod ‘A’ into
the body opening ‘L’ in the longitudinal
member (Figure 19).
Figure 19. Insert the steel rod.
Page 10 of 19
© 2021 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.
21. Now feed steel rod ‘A’ through hole ‘M’
(upper hole) in the reinforcement plate
(Figure 20).
Figure 20. Feeding the steel rod through the reinforcement
plate.
22. The chisel end of the steel rod is to be fed
far enough to engage the front
reinforcement plate ‘P’ at point ‘O’ such that
it is lodged into the gap between
reinforcement plate ‘P’ and the wall of the
longitudinal member ‘R’ (Figure 21).
Figure 21. Engaging the chisel end of the steel rod inside the
longitudinal member.
Page 11 of 19
© 2021 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.
23. If the steel rod bend angle and chisel point
orientation are created as described the tool
will reach the appropriate point of contact
when it is guided into the holes in the
longitudinal member as described (Figure
22).
Figure 22. Cutaway view of the longitudinal member
illustrating the steel rod positioning.
Page 12 of 19
© 2021 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.
24. The chisel end of the steel rod must be
inserted as shown in Figure 23 with the
wedge engaged consistent with the space
formed by the longitudinal member support
to the longitudinal member housing.
Figure 23. The chisel end of the steel rod properly engaged
with the reinforcement plate.
Page 13 of 19
© 2021 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.
25. Figure 24 shows an incorrect engagement of
the chisel end.
Figure 24. Incorrect engagement of the chisel end.
26. Using a marker mark the point at which the
steel rod makes contact with the longitudinal
member. Then make a mark 10mm – 15mm
rearward of that contact point on the steel
rod (Figure 25).
Figure 25. Marking the steel rod.
Page 14 of 19
© 2021 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.
27. Using a hammer drive the steel rod a
distance of 10 mm. Then pull the bending
tool out of the longitudinal member again
(Figure 26).
Figure 26. Steel rod driven forward at least 10mm.
28. As a result, a distance of approximately 3
mm is created between reinforcement plate
‘P’ and the longitudinal member ‘R’.
Separating this point of contact eliminates
the noise generation (Figure 27).
Figure 27. 3mm gap created between reinforcement plate
and longitudinal member.
Page 15 of 19
© 2021 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.
29. All points that were contacted and / or struck
are likely have had their corrosion protective
layer compromised. Because of this
thoroughly coat all areas with cavity way
(Figure 28).
Figure 28. Cavity wax applied.
30. Cavity wax can be applied through the
openings shown in figure 28. The separation
point in the longitudinal member can be
accessed through hole ‘S’ (Figure 29).
Reassemble the vehicle as per the repair
manual.
Figure 29. Access opening for cavity wax application.
31. Perform a final test drive to confirm elimination of the noise by duplicating the driving conditions specified by
the customer. Ensure that the noise has been eliminated to the customer’s satisfaction by driving with the
customer at the time they take possession of the vehicle after repair.
Page 16 of 19
© 2021 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.
Warranty
Claim Type:
 110 up to 48 Months/50,000 Miles.
 If the vehicle is outside any warranty, this Technical Service Bulletin is informational
only.
Service Number:
5079
Damage Code:
0010
Labor Operations:
Check longitudinal member
5079 9999
40 TU
Modify longitudinal member
5080 9999
100 TU
Check longitudinal members – Both sides
5079 9999
40 TU
Modify both longitudinal members
5080 9999
130 TU
GFF
No allowance
0 TU
3 Road tests prior to the service procedure
0121 9999
30 TU
Road test after the service procedure
0121 0004
10 TU
Or
Diagnostic Time:
Claim Comment:
As per TSB #2062633/1
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
Page 17 of 19
© 2021 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.
D 330 KD1 A2
-or-
D 330 KD2 A1
Or the following
alternative product
available from the
Top Service
Supplies and Touch
Up Paint estore:
08852 3M™ Cavity
Wax
Page 18 of 19
© 2021 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.
See ETKA
02
Bolt hex head
Additional Information
All parts and service references provided in this TSB (2062633) are subject to change and/or removal.
©2021 Audi of America, Inc. All rights reserved. The 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 19 of 19
© 2021 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.