A5023122062633_2

Technical Service Bulletin
50 Creaking noises heard when body twists during braking or steering maneuvers
50 23 12 2062633/2 March 17, 2023. Supersedes Technical Service Bulletin Group 50 number 21-06 dated
March 19, 2021, for reasons listed below.
Model(s)
Year
A4
2017 – 2023
A4 allroad, S4,
A5, A5 Cabriolet,
A5 Sportback,
2018 – 2023
S5, S5 Cabriolet,
S5 Sportback,
RS 5
2018 – 2019
2021 – 2023
RS 5 Sportback
2019
2021 - 2023
VIN Range
Vehicle-Specific Equipment
All
Not Applicable
Condition
REVISION HISTORY
Revision
Date
Purpose
2
-
Revised Header (Model Year 2023 added)
Revised Warranty (SRT change)
Revised Required Parts and Tools (Change in cavity wax material)
1
03/20/2021
Initial publication
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
Page 1 of 20
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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
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.
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
frontmost 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.
Page 2 of 20
© 2023 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
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.
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).
Page 3 of 20
© 2023 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
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).
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.
Page 4 of 20
© 2023 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
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.
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.
Page 5 of 20
© 2023 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
11. Remove grommet ‘H’ from the
longitudinal member (Figure 9).
Figure 9. Remove grommet ‘H’.
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.
Page 6 of 20
© 2023 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
Figure 11. Impact protector removed.
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.
Page 7 of 20
© 2023 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
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.
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.
Page 8 of 20
© 2023 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
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.
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.
Page 9 of 20
© 2023 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
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.
19. Measure and verify this distance
(Figure 18).
Figure 18. Verifying distance of 43mm in the bend.
Page 10 of 20
© 2023 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
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.
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.
Page 11 of 20
© 2023 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
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 12 of 20
© 2023 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
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 13 of 20
© 2023 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
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 14 of 20
© 2023 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
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 15 of 20
© 2023 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
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 16 of 20
© 2023 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
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.
Warranty
Page 17 of 20
© 2023 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
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 0199
40 TU
Modify longitudinal member
5079 4199
100 TU
Modify both longitudinal members
5079 4299
130 TU
GFF
No allowance
0 TU
3 Road tests prior to the service procedure
0121 0199
30 TU
Road test after the service procedure
0121 0004
10 TU
Or
Diagnostic Time:
As per TSB 2062633/2
Claim Comment:
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 18 of 20
© 2023 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
D 321 M15 M1
01
Anti-Corrosion Wax
Or the following alternative product available from the Top Service Supplies and Touch Up Paint estore:
08852 3M™ Cavity
Wax
Shop Supply
Cavity Wax
Page 19 of 20
© 2023 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
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.
©2023 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 20 of 20
© 2023 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.