2021 Audi Brake Pad Wear Indicator Warning TSB 2061403/1

Audi has released Technical Service Bulletin (TSB) 2061403/1 to address a specific issue affecting various 2021 Audi models, including the A4, A5, S4, S5, and RS 5. This bulletin details a condition where the "brake pad wear indicator" illuminates in the instrument cluster prematurely, even though the brake pads themselves have not reached their wear limit. This TSB provides guidance for technicians to diagnose and resolve this false warning.

Symptoms

Owners of affected vehicles may observe the following:

• The dashboard displays the message: "The brake pad wear indicator is displayed in the instrument cluster."

This warning appears despite the vehicle's brake pads having sufficient material remaining and not yet reaching their actual wear limit.

Diagnosis and Trigger Conditions

The root cause identified in TSB 2061403/1 for the false "Audi brake pad wear indicator" warning is an improperly crimped wire within the brake pad wear sensor connector. Specifically, the brake pad wear sensor wire may not be correctly crimped to the pin of the sensor connector. This manufacturing anomaly can lead to an incorrect signal, triggering the warning light.

During diagnosis, a technician will first confirm that the brake pads are indeed not worn and that the sensor is properly connected. The next step involves inspecting the crimp on the harness side of the brake pad wear connector. If the wire strands are not protruding past the crimp sleeve, as illustrated in Figure 2 of the TSB, it indicates an improper crimp. Conversely, if the wire is crimped properly (Figure 1), this TSB does not apply, and further diagnosis for other potential issues would be necessary.

Repair Procedure Summary

The repair for this condition involves inspecting the brake pad wear sensor wire crimp and, if found faulty, replacing the affected harness.

1. Initial Verification: A technician will first confirm that the brake pads have not reached their wear limit and that the sensor is securely connected.
2. Crimp Inspection: The crimp on the harness side of the brake pad wear connector will be carefully inspected. The technician will look for instances where the wire strands do not protrude past the crimp sleeve, indicating an improper crimp.
3. Harness Replacement: If an improperly crimped wire is identified, the affected harness for the front wheel speed sensor and brake pad wear indicator must be replaced. Technicians will use ETKA illustration 927-010 to identify the correct replacement harness.
4. Reassembly and Testing: After replacing the harness, the wheel and front wheel arch liner will be reinstalled, and the vehicle will undergo a road test to confirm the "Audi brake pad wear indicator" warning has been resolved.

Required Tools or Parts

To perform this repair, technicians may need the following:

• Fasteners, bolts, nuts, and screws as specified in the Repair Manual and found via ETKA.
• A repair kit for the front speed sensor and brake pad wear indicator, if needed, as determined by ETKA.

Important Warnings

Owners should be aware of a critical diagnostic step:

• If the brake pad wear sensor wire is found to be crimped properly, this TSB 2061403/1 does not apply to the vehicle's issue. In such cases, technicians should proceed with standard diagnostic procedures to identify the actual cause of the warning light.

Warranty Information

This repair is covered under Audi's warranty, subject to specific conditions:

• Claim Type 110: Applies to vehicles up to 48 months or 50,000 miles, whichever comes first.
• Claim Type G10: Applies to Audi Certified Pre-Owned (CPO) vehicles, provided ownership is verified.

For vehicles outside these warranty parameters, this Technical Service Bulletin serves as informational guidance for diagnosis and repair. All warranty claims must adhere to the Audi Warranty Policies and Procedures Manual.

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Source: NHTSA ID: 10183456