2021 Audi A4, A5, S4, S5 Creaking Noise TSB

Owners of certain 2021 Audi A4, A5, S4, and S5 models may experience a persistent "creaking or knocking type noise" emanating from the rear of the cabin. While the official title of Audi Technical Service Bulletin (TSB) 2071019/1 mentions an "Instrument cluster driver information system display is blank" issue, the detailed content of this bulletin specifically addresses this Audi A5 creaking noise and similar sounds originating from the rear cargo area. This TSB outlines a comprehensive repair procedure to eliminate these disruptive noises, ensuring a quieter ride for affected vehicles.

Symptoms

The primary symptom addressed by TSB 2071019/1 is a "creaking or knocking type noise" heard from the rear of the cabin. This noise typically occurs when driving on rough pavement or when the vehicle is subjected to thrusting forces during cornering maneuvers.

Diagnosis / Trigger Conditions

Audi technicians can replicate the creaking or knocking noise under specific driving conditions, such as rough pavement or aggressive cornering. Workshop findings indicate that the noises originate from the sheet metal overlap of the left rear side panel and the left rear cross panel within the rear cargo area.

Before initiating the repair detailed in TSB 2071019/1, technicians are instructed to consult TSB 2068691 (55 Noises from rear of vehicle / rear lid while driving). This is to rule out noises caused by contact points between the rear lid and its adjusting buffer. If corrections from TSB 2068691 have been applied and resolved any rear lid noises, or if the rear lid contact is not the source of the sound, then the welding procedure described in TSB 2071019/1 should be followed.

Important Warnings

• Specialized Repair Requirement: The repair procedure outlined in Audi TSB 2071019/1 demands specialized tools, materials, and specific training. Consequently, this repair "must be performed at an Audi certified collision center" to ensure proper execution and safety.
• Drilling Precaution: During the drilling phase of the repair, it is absolutely crucial that "All 3 of these holes must not penetrate panel 3 (left rear side panel)." This strict instruction is vital for maintaining the structural integrity of the vehicle and ensuring the effectiveness of the repair.

Repair Procedure Summary

The repair detailed in Audi TSB 2071019/1 involves a precise welding process to address the sheet metal overlap causing the Audi A5 creaking noise or knocking sound. This procedure is designed to permanently eliminate the source of the noise.

1. Access Rear Cargo Area: The process begins by detaching the left rear luggage compartment side trim panel. This step requires adherence to specific instructions found in the Elsa repair manual, under the path: "Body>>Body Interior>>70 Interior Trim>>Luggage Compartment Trim Panels>>Luggage Compartment Side Trim Panel, Removing and Installing."
2. Prepare for Welding: Once the problematic area is exposed, three precise holes must be drilled. An 8 mm spot weld drill bit, such as the VAS6322A/2, is used for this task. These holes are strategically positioned: one directly into an existing upper spot weld, a second immediately to its right, and a third on the opposite side of the support panel's radius. It is critical that these drilled holes do not penetrate the left rear side panel (identified as panel 3).
3. Surface Preparation: Following drilling, the area designated for welding is thoroughly ground down and deburred. This action removes any residual primer or contaminants, creating a clean and optimal surface for welding. A drift tool is then utilized to push the support panel as closely as possible to the overlapping left rear side and cross panels, effectively eliminating any potential gaps.
4. Welding Process: If deemed necessary, a test weld may be performed to fine-tune the welding equipment settings for optimal results. Subsequently, all three prepared holes are welded completely closed, securing the panels together.
5. Corrosion Protection and Sealing: After the welding is complete, the welded surfaces are meticulously cleaned. Corrosion protection is then thoroughly restored to the area using a brush. Once the corrosion protection has cured, the entire work area is sealed with cavity wax, specifically D 308SP5M1 or an equivalent product like 3M™ 08852.
6. Final Steps: The final stages involve reinstalling the luggage compartment trim. A comprehensive test drive is then conducted to confirm that the creaking or knocking noise has been successfully resolved, ensuring the vehicle's quiet operation.

Required Tools or Parts

To perform the repair outlined in TSB 2071019/1, specific tools and materials are required:

• Anti-corrosion wax: Part Number D 308SP5M1 (Quantity: 0.3)
• Cavity Wax Plus: 3M™ 08852 (Note: This is considered a shop supply and is not permitted for accounting under warranty/goodwill claims).
• Spot Weld Breaker: Tool Number VAS6322A
• 8 mm spot weld drill bit: For example, VAS6322A/2

Warranty Information

This repair is covered under Audi's warranty for up to 48 months or 50,000 miles, whichever occurs first. If your vehicle falls outside this specified warranty period, the Technical Service Bulletin serves as informational guidance for addressing the issue. The following codes are relevant for warranty claims:

• Service Number: 5368
• Damage Code: 0020
• Labor Operations:
  • Sublet labor operation listed in Outside Labor A0001600: 240 TU
  • Diagnostic Time (GFF): No allowance (0 TU)
  • Road test prior to service procedure (0121 0002): 10 TU
  • Road test after service procedure (0121 0004): 10 TU
• Claim Comment: As per TSB 2071019/1

NHTSA Source Citation

NHTSA ID: 10239684