A4223542038689_8

Technical Service Bulletin
42 Rattle noise from the rear suspension
42 23 54 2038689/8 December 12, 2023. Supersedes Technical Service Bulletin Group 42 number 23-53 dated
August 4, 2023 for reasons listed below.
Model(s)
Year
All Audi Vehicles 2020 – 2025
VIN Range
Vehicle-Specific Equipment
Not Applicable
Not Applicable
Condition
REVISION HISTORY
Revision
Date
Purpose
8
-
Revised Service (Updated procedure)
7
08/04/2023
Revised header (Added Model Years)
6
03/16/2022
Revised header (Added Model Year)
Revised Warranty (Added Warranty Table)
Customer states:
• Clunking or rattling noises are heard from the rear suspension area when the vehicle is driven over bumps.
Technical Background
These noises can be caused by an improperly seated rear bump stop (which occurs when the rear bump stop
was not fully inserted into the rear shock absorber mounting during PDI).
A bump stop installation tool (SET900) was developed to aid with the installation of rear bump stops during PDI
(Figure 1). This tool provides the necessary leverage to seat the rear bump stop in the shock absorber mounting.
Figure 1. The SET900 bump stop installation tool.
© 2023 Audi of America, Inc.
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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
One SET900 tool was sent to all Audi dealers in November 2014. Additional tools can be purchased
through the Audi Special Tools and Equipment Program
Production Solution
Not applicable.
Service
To ensure proper installation of rear bump
stops (in Audi models without air
suspension):
1. Clean the top of the rear bump stops
and coat with tire mounting paste.
2. Use the SET900 special tool to fully
press the rear bump stops into the
upper shock mounts (Figure 2).
3. The purpose of the tool is to properly
seat the rear bump stops in the rear
shock mounts (Figure 3), which will
prevent them from dropping out of the
rear upper shock mounts and causing
the noise.
Figure 2. The SET900 tool being used to install a rear bump
stop.
© 2023 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. Comparison between rear bump stop installation
without and with the SET900 tool.
Always ensure that the dust boot does not get caught on the top of the shock once the vehicle
is lowered.
Tip: A video demonstrating the use of
this tool is available at: https://audiexternal.kzoplatform.com:443/swf/pla
yer/286 (Figure 4).
See TSB 2039206: 00 Viewing TSB videos
for more information about viewing videos.
© 2023 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 4. QR code for viewing the video with a QR code
reader on phones and tablets. Alternatively, the video can
be accessed through computer internet browsers at the link
provided in this bulletin.
4. If the buffer stops were damaged during the vehicle transport, try to shape them correctly by warming them up
slightly using a heat gun. If this is not possible, replace the affected components.
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:
4298
Damage Code:
0020
Labor Operations:
Secure rear axle buffer stop
4298 1399
10 TU
Secure two rear axle buffer stops
4298 1499
20 TU
Replace rear axle buffer stop
4298 5599
90 TU
Replace rear axle buffer stop (Magnetic
Ride)
4298 5599
100 TU
Replace two rear axle buffer stops
4298 5699
140 TU
Replace two rear axle buffer stops
(Magnetic Ride)
4298 5699
160 TU
GFF
No allowance
0 TU
Road test prior to the service procedure
No allowance
0 TU
Road test after the service procedure
0121 0004
10 TU
Diagnostic Time:
Claim Comment:
As per TSB 2038689/8
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
© 2023 Audi of America, Inc.
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Quantity
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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
See ETKA
Fasteners, Bolts, Nuts, and Screws as needed per the Repair
Manual
See ETKA/ELSA
See ETKA
Buffer Stop
01/02
Tool Number
Tool Description
SET900
Bump stop installation tool
Additional Information
The following Technical Service Bulletin(s) will be necessary to complete this procedure:
• TSB 2039206: 00 Viewing TSB videos.
All parts and service references provided in this TSB (2038689) are subject to change and/or removal. Always
check with your Parts Department and/or ETKA for the latest information and parts bulletins. Please check the
Repair Manual for fasteners, bolts, nuts, and screws that require replacement during the repair.
©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.
© 2023 Audi of America, Inc.
Internal
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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.