2021 Audi A6/A7/S6/S7 Creaking Noise TSB 2061672/3

Symptoms

Owners of affected 2021 Audi A6, A7, S6, S7, A6 allroad, RS 6 Avant, A7 e quattro, and RS 7 vehicles may experience a distinct creaking noise. This noise is typically heard in the floor area and can be generated during strong braking or steering maneuvers, especially when the vehicle body is twisting. Workshop findings confirm the noise radiates from the footwell to the area under the seat.

Technical Background

Audi has identified that the underlying cause of this 2021 Audi A6 creaking noise and similar sounds in related models is the contact between the longitudinal members and their internal support plates. This contact occurs during dynamic driving conditions such as cornering or hard braking, which induce twisting forces on the vehicle's body structure.

Audi has implemented a production solution by improving the construction of the longitudinal member assembly in newer vehicles to prevent this issue.

Important Warnings for Owners

• Subframe Bolts: At the conclusion of the repair, it is necessary to replace all loosened subframe bolts. Your service technician will ensure this is done as part of the procedure.
• Body Plug Replacement: The body plug removed during the repair process must be replaced with part number 8K0 805 267.
• Warranty Coverage: If your vehicle is outside the standard 48-month/50,000-mile warranty period, this Technical Service Bulletin 2061672/3 serves as informational guidance only, and repair costs may not be covered.

Repair Procedure Summary

To address the 2021 Audi A6 creaking noise, technicians follow a specific diagnostic and repair process outlined in TSB 2061672/3:

1. Noise Duplication: The technician will first attempt to duplicate the creaking noise on a test drive, ideally with the customer present, to clearly identify the conditions under which it occurs.
2. Initial Diagnosis: The front-most bolt on the subframe mounting is loosened several turns (but not removed). A test drive is then performed. If the noise characteristics change or are eliminated, the TSB repair is likely effective.
3. Temperature Management (if needed): If the noise is difficult to reproduce when the vehicle is cold, the technician may warm the longitudinal member/body near the rear transverse link using a hot air blower to a surface temperature of approximately 65°C (149°F). After cooling to about 30°C (86°F), another test drive is conducted.
4. Access and Foam Removal: The center cover plate on the affected side is lowered, and the first body plug aft of the transverse link connection is removed. Sections of acoustic foam within the longitudinal member area are carefully removed using long needle-nose pliers to provide access to the internal support plates.
5. Tool Fabrication and Modification: An improvised tool is created from an 8mm diameter, 60cm long steel rod. One end of this rod is ground into a chisel shape, approximately 15mm long.
6. Longitudinal Member Modification: The chisel end of the steel rod is inserted through the remaining acoustic foam to engage the longitudinal member support. Using a hammer, the rod is driven 4-5 cm into the longitudinal member support. The tool is then removed.
7. Final Verification: A final test drive is performed with the customer to confirm the complete elimination of the creaking noise.

Required Tools and Parts

Technicians will need to consult ETKA/ELSA for the latest information on fasteners, bolts, nuts, and screws required for the repair. Specific parts mentioned in TSB 2061672/3 include:

• Drain tube grommet: Part Number 8K0 805 267 (Quantity: 2)
• Bolt hex head: Part Number N 91247202 (Quantity: 2)
• Improvised Tool: A steel rod, 8mm in diameter and 60 cm long, with one end ground to a chisel shape.

Warranty Information

This Technical Service Bulletin applies to vehicles within the 110 up to 48 Months/50,000 Miles warranty period. For vehicles outside this coverage, the bulletin is for informational purposes only. The Service Number for this repair is 5079, and the Damage Code is 0010. Labor operations include:

• Center cover plate remove and reinstall: 5193 1900
• Modify longitudinal member: 5079 4199 (80 TU)
• Center cover plate remove and reinstall – Both sides: 5193 2000
• Modify both longitudinal members: 5079 5099 (130 TU)

Diagnostic time is listed as GFF with no allowance (0 TU). Road tests prior to service procedure (0121 0199) are allocated 30 TU, and road tests after service procedure (0121 0004) are allocated 10 TU. All warranty claims must adhere to the Audi Warranty Policies and Procedures Manual.

Revision History

This bulletin, 50 23 11 2061672/3, was initially published on December 16, 2020. It supersedes Technical Service Bulletin Group 50 number 21-08, dated September 22, 2021. Revisions include:

• Revision 2 (09/22/2021): Revised service instructions to include the required diameter of the steel rod and updated Warranty SRT.
• Revision 3: Updated Warranty Labor Operations.

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Source: NHTSA ID 10232093, Audi Technical Service Bulletin 2061672/3