2021-2024 Audi A5 Bonded Outer Door Seal TSB 2076939/1

Audi has issued Technical Service Bulletin (TSB) 2076939/1 to address instances where the bonded outer door seal is coming loose from the door on certain 2021-2024 Audi A5 models. This bulletin, released on February 17, 2025, supersedes an earlier TSB, 2064183, and provides detailed instructions for technicians to diagnose and repair this condition.

Symptoms

Owners may observe that the door seal has come loose from the door frame. This can affect either the main outer door seal or the auxiliary door seal, on any of the vehicle's doors.

Technical Background and Diagnosis

According to Audi, the adhesive bond for the outer door seal can come loose in the entire area where it contacts the door. Various environmental factors, such as pressure, temperature fluctuations, and the presence of dirt in the bonding area, can influence the integrity of this adhesive bond. Technicians will inspect the door seals to confirm that the adhesive bond has failed, leading to the Audi A5 door seal loose condition.

Repair Procedure Summary

To resolve the Audi A5 door seal loose issue, technicians are instructed to replace the affected door seals following the procedures outlined in the Workshop Manual. Key requirements for a successful repair include:

• Ensuring both the vehicle and the new seal are at room temperature before starting work.
• Thoroughly cleaning the bonding surfaces to ensure they are free of dirt and grease.
• Exercising caution during installation to avoid scratching the new seal.

After the new seal is installed, the door must not be closed for at least 30 minutes to allow the adhesive to properly set. If a door was renewed, the routing of the outer door seal on the opposite side should be used as a guide for positioning. The bonding surface on the painted area of the vehicle body must be cleaned using adhesive strip remover VAS 6349 and cleaning solution D 009 401 04 to ensure proper adhesion.

Required Parts and Tools

Technicians will need specific materials to perform this repair, including:

• Bonding agent: Part number D 355 205 A2
• Applicator: Part number D 009 500 25
• Adhesive strip remover: VAS 6349
• Cleaning solution: D 009 401 04
• Fasteners, Bolts, Nuts, and Screws: As needed per the Repair Manual (refer to ETKA/ELSA for specific details).

Warranty Information

Warranty claims related to this TSB must adhere to the Audi Warranty Policies and Procedures Manual. The claim comment should reference TSB 2076939/1. The following service and damage codes are relevant:

• Service Number (Front outer door seal): 5765
• Service Number (Rear outer door seal): 5864
• Damage Code: 0018

Labor operations include:

Labor Operation	Description	Time Units (TU)
5765 1900	Remove and install front outer door seal	See SRT
5765 2099	Remove and install 2 front outer door seals	100
5864 1900	Remove and install rear outer door seal	See SRT
5864 2099	Remove and install 2 rear outer door seals	120

Important Warnings

If your vehicle is outside of its warranty period, this Technical Service Bulletin is for informational purposes only, and repair costs may not be covered by Audi.

Source: NHTSA ID 11015753