A3922472064024_2

Technical Service Bulletin
39 Oil leak at sealing cap on rear final drive, sport differential
39 22 47 2064024/2 April 29, 2022. Supersedes Technical Service Bulletin Group 39 number 21-44 dated
August 26, 2021, for reasons listed below.
Model(s)
Year
VIN Range
Vehicle-Specific Equipment
All
Rear Differential
S4, S5
Cabriolet,
S5
2020 – 2022
Sportback,
and SQ5
S8, SQ7,
SQ8, and RS 2020 – 2021
Q8
RS 5, RS 5
Sportback,
2021 – 2022
and SQ5
Sportback
RS 6 Avant,
and RS 7
2021
Condition
REVISION HISTORY
Revision
Date
Purpose
2
-
Revised Header (Added S4, S5, RS5, and SQ5)
1
08/26/2021
Initial publication
Customer states:
• There is an oil leak from the rear of the vehicle.
© 2021 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
Workshop findings:
• An oil leak is confirmed from the top of
the differential near the output flanges.
• One or both of the sealing caps are
missing from the pressure limiting
valves (Figures 1 - 3).
Figure 1. Missing sealing cap viewed with a pocket mirror.
Figure 2. Location of sealing caps on the 0D3 differential.
© 2021 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
Figure 3. Location of sealing caps on the 0BX differential.
Technical Background
Not applicable.
Production Solution
Not applicable.
Service
If the leak can be confirmed to be from a missing sealing cap, then perform the following repair.
The following parts are required to perform the repair:
• Repair Kit 0BX 598 080 contains two sealing caps and one special installation drift for the repair.
• Locking fluid, 10ml D 154 100 A1.
• Silicone adhesive sealant, 50ml D 176 501 A1.
© 2021 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
1.
Following the Elsa Repair Manual instructions remove the differential from the vehicle and place it
on a suitable working surface.
Note:
The clutch valves can be damaged if subjected to impact. Place a rubber mat or hard foam slab
underneath the differential.
2.
Clean the rear differential around the pressure limiting valve (sealing cap missing) with a clean
cloth. If only one sealing cap is missing, do not attempt to remove the installed cap.
Note:
The bolt head on the pressure limiting valve (hexagon socket head bolt in the hole) must not be
turned.
Note:
Chemical agents (brake clean etc.) must not enter the system. Do not let chemical agents get into
the exposed pressure limiting valve.
Tip: Steps 3 to 7 must be performed within 5 minutes (due to hardening of locking fluid).
3.
Place the new sealing cap on a drift and
coat it lightly with locking fluid around the
outside edge (red arrow Figure 4).
Figure 4. Sealing cap on a drift.
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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
4.
Knock sealing cap onto pressure limiting
valve using a drift and soft-faced hammer
at a right angle to machined surface of
housing until it reaches its stop. When it
reaches its stop, a dull sound can be heard
and a spring-back effect can be felt at the
hammer (Figure 5).
Figure 5. Installing sealing cap
5.
Remove excess locking fluid with a clean cloth.
6.
Perform a visual check to see whether the sealing cap has been installed evenly around the entire
circumference.
7.
Perform a check measurement with a caliper gauge. The measurement from the machined surface
of the housing (the red area in Figure 6) to the upper collar of the sealing cap (green arrows in
Figure 6).
This measurement must be performed in three locations at intervals of 120°and a minimum
dimension of 1.00 mm and a deviation of no more than 0.3 mm must be ensured.
In the event of deviations from the minimum dimension or the maximum deviation being
exceeded, the sealing cap can be knocked carefully in with the drift and soft-faced hammer if
necessary.
Note:
It is not permitted to remove a sealing cap that has already been installed.
© 2021 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
Figure 6. Measurement locations.
8.
Figure 7. Performing measurement.
If both sealing caps were missing, then follow the above instructions in steps 3 through 7 to install
the 2nd cap.
The following section of the repair instructions must be performed both for the renewed sealing caps
and for sealing caps that are still fitted from the factory. The sealing caps for pressure limiting valves on
both sides must be bonded on.
9.
After a drying time of at least 30 minutes, clean the area around the sealing caps of the pressure
limiting valves (both sides) using a clean cloth (lightly coated with brake cleaner if necessary).
10. Both sealing caps must be bonded over the entire surface using the silicone adhesive sealant. A
layer of skin forms and then hardens (Figures 8 - 9). A drying time of at least 30 minutes must be
ensured before reinstallation into the vehicle.
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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
Figure 9. Silicone adhesive sealant example 2.
Figure 8. Silicone adhesive sealant example
1.
11. Following the repair manual, reinstall the differential into the vehicle. Take care not to touch the
silicone sealant as it takes a long time to completely harden.
12. Check ATF level of differential in accordance with Elsa Repair Manual and top up if necessary.
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:
3989
Damage Code:
0050
© 2021 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
Labor Operations: Remove and install rear final drive
3988 19XX
See SRT with
associated
operations
3989 5199
90 TU
Check and top up ATF for the rear final drive 0156 3599
20 TU
GFF – Checking and clearing fault codes
included in existing labor operations
No allowance
0 TU
Road test prior to service procedure
No allowance
0 TU
Road test after service procedure
0121 0004
10 TU
Seal housing for the rear final drive
Diagnostic Time:
Claim Comment:
As per TSB 2064024/2
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
0BX598080
Repair kit for sealing cap
01
D154100A1
Locking fluid 10ml
01
N 90281802
Seal Bolt with seal ring
01
D176501A1
Silicone adhesive sealant 50ml
01
Additional Information
All parts and service references provided in this TSB (2064024) are subject to change and/or removal.
©2022 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
Page 8 of 9
© 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.
Technical Service Bulletin
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.
© 2021 Audi of America, Inc.
Page 9 of 9
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.