34 13 13 2028650

Technical Service Bulletin
34, 37 Grinding or wheel bearing type noises from front when accelerating or at constant speed
34 13 13 2028650/2 January 15, 2013. Supersedes Technical Service Bulletin Group 34 number 12-08 dated
February 21, 2012 for reasons listed below.
Model(s)
Year
VIN Range
Vehicle-Specific Equipment
S4 and S5
2010-2011
All
All with DSG Transmission
A4, A4
Cabriolet, A5,
A5 Cabriolet
2009-2011
All
All with CVT Transmission
A5, S5
2008-2011
All
All with Manual Transmission
A4, S4 cabriolet
2009-2011
All
All with Manual Transmission
Condition
REVISION HISTORY
Revision
Date
Purpose
2
-
Revised Required Parts and Tools (Shim quantity)
Revised Service (Formatted for clarity)
1
2/21/12
Original publication
Customer states constant howling, droning, or scraping noises heard from the front of the vehicle when
accelerating lightly.
© 2013 Audi of America, Inc.
Page 1 of 10
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
Technical Background
The ball bearing for the left
flange shaft spins in the
gearbox housing because of a
gap between the outer bearing
ring and the support bracket.
This can result in grinding
marks and swarf (Figure 1,
Figure 2).
Figure 1. Grinding marks and swarf in gearbox housing.
Figure 2. Grinding marks and swarf on flange housing and
bearing.
Tip: The affected ball bearings are only fitted on the left side; therefore, the complaints do
not occur on the right side.
© 2013 Audi of America, Inc.
Page 2 of 10
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
Note:
After a removal of the bolts to check for this condition, the bolts must always be replaced by new parts (new part
number: N 91208801).
Production Solution
Not applicable.
Service
Try to reproduce the customer complaint so that it can be clearly assigned to this TSB by
removing the support bracket and checking for wear marks. If wear marks are present as
shown in Figure 1 or Figure 2 above, follow checks and repair instructions below:
On V6 and V8 engines:
1. Remove the gearbox according to the repair manual.
2. Loosen the support bracket of the left final drive (if necessary) and pull the left flange shaft
out of the gearbox according to the repair manual, taking care not to damage the shaft seal.
3. Proceed to Checks Section below.
On all models with 4 cylinder engines:
1. Remove the left drive shaft according to the repair manual.
2. Remove the brake caliper and hang caliper off to the side without stressing the brake hose.
3. Detach the suspension strut from the lower control arm, and the suspension strut from the
sway arm link. (Loosen upper bolts for the strut if needed to allow for more clearance).
4. If necessary for bearing housing clearance, remove the upper control arm bolt and allow
bearing housing to swing out of the way.
5. Remove any shielding from the axle opening.
© 2013 Audi of America, Inc.
Page 3 of 10
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
6. Pull the left flange shaft out of the
gearbox (according to the repair
manual) (Figure 3). Support the
flange shaft through the lower
opening on the gearbox (service flap)
to avoid damaging the oil seal
between differential and gearbox
housing (Figure 4).
Figure 3. Pulling out the flange shaft.
Note:
After a removal, the bolts must
always be replaced by new parts
(new part number: N 91208801).
Figure 4. Supporting the flange shaft.
7. After removing the flange shaft visually check the oil seal between differential and gearbox
housing with a lamp through the lower gearbox opening (service flap) for damage.
Note:
Remove bearing and bearing bracket from axle and discard. Use new bearing for
measurements.
8. Proceed to Checks Section below.
© 2013 Audi of America, Inc.
Page 4 of 10
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
Checks Section:
The following steps assist in determining
how many shims must be fitted between
bearing and gearbox housing to make the
bearing extend out from the case a
minimum of 0.5mm to 0.8 mm (Figure 5).
Figure 5. Bearing example.
Tip: Bearing in Figure 5 is only for demonstration purposes. Always measure using a
new bearing.
Determine the number of shims to be fitted:
1. Use size 600 grit sandpaper to remove any corrosion or dirt on the gearbox flange surface.
Do not clean the bearing carrier.
2. Measure whether the gap between bearing and gearbox housing is flush or extended from
case.
3. Use a straightedge on two different
positions on the bearing and on the
gearbox housing (this leads to four
measuring positions) (Figure 6).
Figure 6. Apply straightedge on gearbox
housing/bearing.
© 2013 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
4. Determine the value with a feeler gauge
on four different points (Figure 7).
Tip: Bearing in Figure 7 is only for
demonstration purposes. Always
measure using new bearing.
Figure 7. Measuring gap
5. After the measuring, calculate how many shims must be fitted between bearing housing
and bearing. Each shim is 0.30 mm. Examples:
Below flush gap (Figure 8):
Measured values: Top 0.10 mm, bottom
0.15 mm, left 0.15 mm, right 0.10 mm
Biggest measured value: 0.15 mm
For the calculation the value must be
given a negative algebraic sign.
- 0.15 mm
+
0.30 mm
=
0.15 mm
+
0.30 mm
=
0.45 mm
+
0.30 mm
thickness of 1st shim
thickness of 2nd shim
thickness of 3rd shim
= 0.75 mm minimum is reached
(0.5- 0.8 mm)
Figure 8. Determine the below flush value.
Three shims are needed.
Note:
Although the bearing may extend from the case as shown, the distance may not be enough
to hold the bearing tight. Measure as follows to determine and correct.
© 2013 Audi of America, Inc.
Page 6 of 10
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
Extended from case gap (Figure 9):
Measured values: Top 0.10 mm, bottom
0.15 mm, left 0.10 mm, right 0.10 mm
Smallest measured value:
0.10 mm
+
0.30 mm
=
0.40 mm
+
0.30 mm
1st shim
2nd shim
= 0.70 mm minimum is reached
(0.5- 0.8 mm)
Two shims are needed.
Figure 9. Determine the extended value.
Reassembly:
1. Install new support bracket and bearing onto the shaft per repair manual, being sure the
part number of the support bracket is pointing outward.
Tip: When fitting the support bracket the part number must point to the outside.
2. Clean the flange shaft with a fluff-free cloth and slightly lube the shaft at the seal contact
area using G 052128A1.
3. Install the shims and feed the shaft back through the opening of the lower gearbox side with
appropriate support, taking care not to damage the seal (Figure 10).
4. Be sure to replace the support bracket
bolts.
Figure 10. Position of shims.
Note:
Because the bearing turns, it may have taken material off of the bearing carrier in axial and
radial directions. The resulting free play can be ignored, as a turning of the outer bearing
ring is prevented by the axial clamping force of the support bracket.
© 2013 Audi of America, Inc.
Page 7 of 10
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
Warning:
Any bolts or fasteners that were removed, loosened, or that are for one-time use must be
replaced per ELSA instructions.
© 2013 Audi of America, Inc.
Page 8 of 10
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
Warranty
Claim Type:
Use applicable claim type. If vehicle is outside any warranty, this Technical Service Bulletin
is informational only.
Service Number:
3437 Manual
3737 Automatic
Damage Code:
0010
Labor Operations: Remove and install drive shaft
4 Cylinder Manual
Check gearbox
transmission
4 Cylinder
Automatic
Transmission
6 and 8 Cylinder
Manual /DSG
Transmission
Diagnostic Time:
4041 1900
90 TU
3435 0199
20 TU
Repair gearbox housing
3437 4199
90 TU
Remove and install drive shaft
4041 1900
90 TU
Check automatic gearbox
3735 0199
20 TU
Repair gearbox housing
3737 4199
90 TU
Remove and install gearbox
3435 19XX
Use labor operation
for appropriate
model/transmission.
Check gearbox
3435 0199
20 TU
Repair gearbox housing
3437 4199
50 TU
GFF
No allowance
0 TU
Road test prior to service procedure
0121 0002
10 TU
Road test after service procedure
0121 0004
10 TU
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 #2028650/2
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.
© 2013 Audi of America, Inc.
Page 9 of 10
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
Tip: For customer satisfaction to reduce time down, it is recommended to pre-order 4 shims (0B4409227)
as most vehicles will require 1 to 4 shims. Return all unused portions.
Part Number
Part Description
Quantity
0B4409294D
Deep-groove ball bearing
1
0B4409175C
0B4409175D
Support bracket (flange for final drive)
0AW and 0B2
Support bracket (flange for final drive)
0B5 and 0B4
1
1
0B4409227
Shims
As needed (4 maximum).
0B4409297
CIRCLIP
1
N 91208801
M8 bolts
3
G 052128A1
Grease for radial oil seal
.25
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.
© 2013 Audi of America, Inc.
Page 10 of 10
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.