2021-2023 Audi A6/A7 Rear Suspension Noise TSB

Symptoms

Owners of certain 2021-2023 Audi A6, A7, S6, S7, RS 6 Avant, RS 7, A6 allroad, and A7 e quattro models may notice specific symptoms related to their vehicle's rear suspension. The primary complaint is "Noises from rear of vehicle when suspension compresses." This Audi A6 rear suspension noise can be indicative of an underlying mechanical issue.

Upon inspection, technicians have found that the coil spring on the rear axle can make contact with either the spring control arm or the track rod. This contact occurs because the spring is not seated centrally in its mounting.

Technical Background

Audi has identified that the root cause of the coil spring contact is a manufacturing tolerance issue. Specifically, the transition point of the coil spring is outside the acceptable tolerance, leading to its improper seating and subsequent contact with adjacent suspension components. An improved production process has been implemented to address this going forward.

Important Warnings

When addressing this rear suspension issue, Audi provides specific instructions to technicians to ensure proper repair and prevent unnecessary parts replacement:

• "Only replace components on the side affected."
• "Do not replace components on the side which is OK as a precaution."

These guidelines emphasize that only components showing abrasion or damage should be replaced, avoiding additional costs or work on perfectly functional parts.

Repair Procedure Summary

For vehicles exhibiting the Audi A6 rear suspension noise, technicians should follow a specific repair procedure outlined in TSB 42 22 47 2065993/1. The process involves several key steps:

1. Inspection: The technician will first check the coil spring, spring control arm, and track rod for any signs of abrasion. Figure 1 in the TSB provides an example of what this abrasion might look like.
2. Component Replacement: If abrasion is found on any of these components, the affected parts, along with the top and bottom spring plates, must be replaced. This ensures that the coil spring is properly seated and no longer makes contact.
3. Wheel Alignment: After any suspension components are replaced, a wheel alignment is required to ensure the vehicle's handling and tire wear are within specifications.

This procedure is detailed in the Repair Manual section for Chassis, Suspension, Wheels, Steering, specifically under 42 Rear Suspension, Suspension Strut, Shock Absorber, Coil Spring.

Required Parts and Tools

To perform the repair described in TSB 42 22 47 2065993/1, specific parts and tools may be required. Technicians are advised to consult their Parts Department and/or ETKA (Electronic Parts Catalog) for the latest information and part bulletins. Generally, this includes:

• Fasteners, Bolts, Nuts, and Screws: As needed per the Repair Manual.
• Coil Spring, Track Rod, Spring plate, Wishbone: These components may need replacement if abrasion is found.

All specific part numbers and quantities can be found in ETKA/ELSA.

Warranty Information

This Technical Service Bulletin outlines the warranty coverage for the repair of the Audi A6 rear suspension noise.

• Claim Type: The repair falls under Claim Type 110 for vehicles up to 48 months or 50,000 miles. For Certified Pre-Owned (CPO) vehicles, Claim Type G10 applies, requiring owner verification.
• Out of Warranty: If the vehicle is outside of any applicable warranty, this TSB serves as informational guidance only, and repair costs may not be covered.
• Service Number: 4272
• Damage Code: 0010
• Labor Operations:
  • Replacing the coil spring, spring plate, track rod, and wishbone on one side (Labor Operation 4272 5599) is allocated 180 TUs (Time Units) for front-wheel drive vehicles and 200 TUs for all-wheel drive vehicles.
  • Replacing these components on both sides (Labor Operation 4272 5699) is allocated 310 TUs for front-wheel drive vehicles and 350 TUs for all-wheel drive vehicles.
• Diagnostic Time: Wheel alignment (4495 0350) is referenced to the Service Repair Time (SRT), and Guided Fault Finding (GFF) (0150 0000) has a maximum of 70 TUs.
• Road Test: No allowance (0 TU) for a road test prior to the procedure, but 10 TUs (0121 0004) are allocated for a road test after the service procedure.
• Claim Comment: All warranty claims must include the comment "As per TSB 2065993/1" and adhere to the Audi Warranty Policies and Procedures Manual.

Owner Action

If you own a 2021-2023 Audi A6, A7, S6, S7, RS 6 Avant, RS 7, A6 allroad, or A7 e quattro and are experiencing noises from the rear suspension when it compresses, it is recommended to schedule an appointment with an authorized Audi dealership. Inform them about the Audi A6 rear suspension noise and mention Technical Service Bulletin 42 22 47 2065993/1. The dealership will be able to diagnose the issue, check for abrasion on the coil spring and suspension links, and perform the necessary repairs under warranty if applicable.

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Source: NHTSA ID: 10207818, Manufacturer Communication Number: 42 22 47 2065993/1