2025 Audi A5/S5 Windscreen Noise TSB 2078650/2

Symptoms of Windscreen or Dash Panel Noise

Owners of certain 2025 Audi A5 and S5 models may notice an unusual noise emanating from the dash panel or windscreen area, particularly when driving over uneven road surfaces. This noise might initially seem to come from the dash, but upon closer inspection or by moving one's head closer to the steering wheel, it can be identified as originating from the upper part of the windscreen. This specific 2025 Audi A5 windscreen noise can be a persistent and irritating issue for drivers.

Technical Background

Audi's workshop findings indicate that the 2025 Audi A5 windscreen noise is caused by the left and right windscreen pins. These pins are integral to the factory assembly process, where they help position and secure the windscreen during bonding to prevent it from slipping before the adhesive cures. Once the windscreen is fully bonded, these pins are no longer functionally required. However, if they remain in place and are subject to movement relative to the vehicle body, they can create the audible noise that owners are experiencing.

Production Solution

Audi is implementing a production change to address the root cause of this 2025 Audi A5 windscreen noise. Starting approximately in week 25 of 2025, new vehicles will be equipped with a revised 2-component windscreen pin. This updated pin features softer plastic in the area that contacts the vehicle body, which is designed to prevent the movement and subsequent noise generation observed with the current pins.

Repair Procedure Summary

Technical Service Bulletin 2078650/2 outlines a specific repair procedure to eliminate the windscreen and dash panel noise. The process involves several steps to access and modify the windscreen pins:

1. Preparation: To gain access to the windscreen pins, technicians must first remove specific interior components. This includes the A-pillar trim on both sides, as well as the left and right sun visors. These parts need to be carefully detached to avoid damage during the repair.
2. Pin Stabilization: Before removing the windscreen pins, a butyl adhesive sealing cord is applied to them. This cord serves a crucial purpose: it prevents the pin from falling into inaccessible areas once it is dislodged. More importantly, it ensures that even if a small piece of the pin remains or if the pin were to somehow move after being knocked out, it would not generate further noise. The TSB specifies using 2x 2 cm of this sealing cord.
3. Pin Removal: Once stabilized with the adhesive cord, the windscreen pins are carefully knocked out. This is typically performed using a narrow, sharp screwdriver or a small chisel, as depicted in the TSB's figures (Figures 5 and 6). The goal is to cleanly dislodge the pins from their position.
4. Post-Removal Handling: After removal, the windscreen pin, now covered with the butyl adhesive sealing cord, can be left within the vehicle's structure (as shown in Figure 8). The adhesive cord ensures that the removed pin or its remnants will not rattle or create new noises.

This procedure directly addresses the movement of the windscreen pins, resolving the 2025 Audi A5 windscreen noise issue.

Required Tools or Parts

To perform the repair outlined in TSB 2078650/2, technicians will need a few specific items:

• Butyl adhesive sealing cord: This material is essential for stabilizing the windscreen pins before removal and preventing future noise.
• Narrow sharp screwdriver or small chisel: These tools are used to carefully dislodge and remove the windscreen pins.

Warranty Information

For eligible vehicles, the repair for the 2025 Audi A5 windscreen noise is covered under warranty. The Technical Service Bulletin 2078650/2 provides specific codes for warranty claims:

• Service Number: 6412
• Damage Code: 0020

Several labor operations are associated with this repair, each with its own code:

• Remove and install 2 upper A-pillar trims: 7057 2000
• Remove and install sun visor: 6823 1950
• Remove and install right sun visor: 6824 1950
• Remove windscreen and left and right windscreen pins: 6410 5099 (10 TU)

All warranty claims must adhere to the Audi Warranty Policies and Procedures Manual. If a vehicle is outside of its warranty period, this Technical Service Bulletin serves as informational guidance only, and repair costs may be the owner's responsibility.

Source: NHTSA ID 11027363