2019-2025 Audi A6/A7/S6/S7/RS6/RS7 Creaking Noise TSB

Owners of certain 2019-2025 Audi models may experience a distinct Audi A6 creaking noise originating from the floor area, particularly during specific driving conditions. This issue, detailed in Audi Technical Service Bulletin 2061672/5, affects models including the A6 (2019-2025), A6 allroad (2020-2025), S6 (2020-2025), RS 6 Avant (2021-2025), A7 (2019-2021), A7 e quattro (2021), S7 (2020-2021), and RS 7 (2021).

Recognizing the Creaking Noise

Customers typically report a creaking type noise heard in the floor area of their vehicle. This Audi A6 creaking noise is most noticeable and can be generated during strong braking or steering maneuvers where the vehicle body is twisted. Workshop findings confirm that the noise originates from the floor area, specifically radiating from the footwell to the area under the seat.

Technical Background

During cornering or hard braking maneuvers, the vehicle's longitudinal members can make contact with their internal support plates, leading to the creaking noise. Audi has implemented an improvement in the construction of the longitudinal member assembly in production to address this issue.

Revision History

This Technical Service Bulletin, 2061672/5, dated September 10, 2024, supersedes Technical Service Bulletin Group 50 number 23-13 dated June 9, 2023. Key revisions include:

• Revision 5: Updated header to include MY 2022 – 2025 A6 models, revised service requirements to add photo/video documentation, and updated required parts and tools (removing a part image).
• Revision 4 (06/09/2023): Corrected labor operations for warranty claims.
• Revision 3 (02/22/2023): Further updated labor operations for warranty claims.

Diagnosing the Creaking Noise

Technicians are instructed to first duplicate the noise on a test drive, ideally with the customer, to confirm the conditions under which the symptom presents. This step ensures the noise originates from the longitudinal member and that the repair outlined in TSB 2061672/5 will be effective.

To begin diagnosis, the front-most bolt on the subframe mounting should be loosened several turns, but not removed (as shown in Figure 1 of the TSB). After this, the vehicle is test driven again. If the noise is not eliminated or changed, the TSB's repair procedure will not be effective, and further diagnosis outside its scope is required.

If the noise is difficult to reproduce when the vehicle is cold, a specific warming procedure is recommended. This involves warming the longitudinal member/body in the area of the rear transverse link bolted connection with a hot air blower set to approximately 550°C (1022°F) (Figure 3), then allowing the surface temperature to cool to approximately 30°C (86°F) (Figures 4 and 5) before re-testing. Merely lowering the vehicle from a hoist after this warming process can also elicit the noise symptom.

Important Owner Information

NOTICE: When performing this repair, the body plug removed in step 9 must be replaced with part number 8K0 805 267.

Detailed Repair Procedure

Once the symptom is confirmed, the repair involves the following steps:

1. Lower the center cover plate on the affected side of the vehicle.
2. Remove the first body plug located aft of the bolted connection for the transverse link (Figure 6).
3. To access the affected area inside the longitudinal member, sections of the acoustic foam are removed using long needle-nosed pliers (Figure 7). It is not necessary to remove all acoustic foam, and the small amount removed does not need to be replaced.
4. An improvised tool must be fabricated from an 8mm diameter, 60 cm long steel rod (Figure 8).
5. The tip of one end of this steel rod is then ground into a chisel shape, with the grind length being approximately 15mm +/-3mm on each side (Figure 9).
6. The chisel end of the steel rod is inserted into the body opening, through the remaining acoustic foam, far enough to engage the longitudinal member support (Figure 10). A cut-away drawing in Figure 11 illustrates the contact area between the longitudinal member support and housing.
7. Figure 12 shows an opened longitudinal member and support for reference.
8. The steel rod is inserted to the point of contact indicated by a red arrow (Figure 13). Figure 14 shows the correct position of the steel rod after insertion and engagement.
9. The chisel end of the steel rod must be inserted correctly, with the wedge engaged consistent with the space formed by the longitudinal member support to the housing (Figure 15). Figure 16 illustrates an incorrect engagement.
10. Using a hammer, the steel rod is driven 4-5 cm into place. Technicians should mark this distance on the rod with tape (Figure 17). The tool is then removed.
11. After the modification, a final test drive is performed with the customer to confirm the elimination of the Audi A6 creaking noise. The noise must be eliminated to the customer's satisfaction.
12. Photos of the customer's concern must be taken and uploaded into DOC-IT with the repair order, including a date stamp and VIN reference.

Required Parts and Tools

• Fasteners, Bolts, Nuts, and Screws: As needed per the repair manual (See ETKA/ELSA).
• 8K0 805 267: Drain tube grommet (1 per side, maximum of 2).
• N 91247202: Bolt hex head (1 per side, maximum of 2).
• Improvised Tool: A steel rod, 8mm in diameter and 60 cm long, with one end ground into a chisel shape (15mm +/-3mm grind length).

Warranty Coverage

Warranty claims for this repair must adhere to the Audi Warranty Policies and Procedures Manual. If the vehicle is outside of warranty, this Technical Service Bulletin serves as informational guidance only.

• Service Number: 5079
• Damage Code: 0010
• Labor Operations and Time Units (TU):
  • Center cover plate remove and reinstall: 5193 1900 (80 TU)
  • Modify longitudinal member: 5079 4999 (80 TU)
  • Alternatively, for both sides:
    • Center cover plate remove and reinstall – Both sides: 5193 2000 (130 TU)
    • Modify both longitudinal members: 5079 5099 (130 TU)
  • GFF (Guided Fault Finding): No allowance (0 TU)
  • 3 Road tests prior to the service procedure: 0121 0199 (30 TU)
  • Road test after the service procedure: 0121 0004 (10 TU)
• Claim Comment: As per TSB 2061672/5

All parts and service references in TSB 2061672/5 are subject to change and/or removal.

NHTSA ID: 10255397 ```