2021-2025 Audi DL382 Transmission Noises TSB 2074806/3

Owners of 2021-2025 Audi A4, A5, A6, A7, and Q5 models equipped with the DL382 transmission may experience unusual noises or vibrations while the vehicle is idling, stationary, or driving. Audi has issued Technical Service Bulletin (TSB) 2074806/3 to guide technicians in diagnosing and resolving these concerns. This TSB, released on May 22, 2025, addresses a range of complaints related to transmission and engine operation.

This bulletin, TSB 2074806/3, outlines specific symptoms, diagnostic methods, and repair steps to ensure proper resolution of the Audi A6 transmission noises and similar issues across affected models.

Revision History

Audi has updated this Technical Service Bulletin multiple times to refine its guidance:

• Revision 3 (May 22, 2025): The title was revised for clarity, and the header was updated to reflect adjusted models.
• Revision 2 (November 22, 2024): The header was revised to include adjusted models.
• Revision 1 (July 31, 2024): This was the initial publication of the bulletin.

Symptoms

Owners might notice several types of noises and vibrations, which can vary depending on the vehicle's state. These symptoms often indicate issues with the transmission's operation, shift, power distribution control, or engine operation:

• "Noises after selecting a gear at idle speed when the vehicle is stationary."
• "Noises when driving in odd-numbered gears (1st, 3rd, 5th gear)."
• "Noises when driving in even-numbered gears (R, 2nd, 4th gear)."
• "Oil loss."
• "Noises from rear of gearbox (Figure 3)." An example of this can be seen in a video linked in the TSB.
• "Noises from the area of the dual-mass flywheel (service flap)."
• "Evidence of ATF loss when the service flap is open."
• "Abrasion visible on the permanent magnets of the oil pan (see Figure 5)." This indicates metallic wear within the transmission.

Technicians are specifically advised that "The noises change when a gear is selected/deselected (Figure 2)" and "The noises change with the engine speed (Figure 4)." These changes provide crucial diagnostic clues.

Diagnosis

To accurately diagnose the source of the Audi A6 transmission noises, technicians are instructed to first reproduce the customer's reported complaint. The TSB emphasizes the importance of documenting findings with audio, video, and detailed photos.

Workshop Findings

Initial workshop findings typically confirm that "The customer complaint(s) can be reproduced" and "The noise in the vehicle interior can be reproduced (see Figure 1)." Video examples are provided for interior noise, noise changing with gear selection, gearbox noise, and noise changing with engine speed.

Visual Inspection

A thorough visual inspection of Bearing A located in the cover for the dual clutch is required. This involves removing the oil seal on Bearing A (as shown in Figure 9) and documenting any visible malfunctions with detailed photos. Technicians should look for wear on Bearing A (Figure 10) or damage to the ball cage (Figures 11, 12, and 13).

Specialized Tool Usage

The Pico NVH tool (VAS 611015) can be used to allocate noises to specific accelerometers (accelerometer 1 and/or 2) and a microphone. This analysis can detect noises within an approximate frequency range of 250-600Hz. The TSB provides diagrams (Figure 6: "Measuring points_page_1") and close-up photos (Figure 7: "Measuring points_page_2") illustrating the correct placement of acceleration sensors and microphones for accurate measurement and analysis. Figure 8, titled "Auswertung der Messung / analysis of the measurement," shows example charts of noise levels in driving positions N and D, helping technicians interpret the data.

Technical Background

The root cause of these noises and vibrations is often related to Bearing A within the dual clutch assembly. Figure 9 provides an exploded view diagram of the dual clutch, clearly labeling "Lager A / Bearing A." Wear or damage to this bearing can lead to the various noise symptoms described.

Repair Procedure Summary

The repair strategy depends on the extent of the damage found during diagnosis. The TSB outlines two primary repair levels for the dual clutch:

1. Bearing A Replacement: If wear is observed on Bearing A and the ball cage is still intact within Bearing A (as depicted in Figure 11), only Bearing A in the dual clutch cover should be replaced.
2. Entire Dual Clutch Replacement: If the ball cage is no longer contained within Bearing A, or if there is irreparable damage to the ball cage (as shown in Figures 11, 12, and 13), the entire dual clutch assembly must be replaced.

Following either of these primary repairs, additional steps are necessary:

• Replace the high-pressure filter, the low-pressure filter, and the intake filter. After removing the filter, thoroughly clean the valve body in this area to prevent contamination.
• Replace the permanent magnets in the gearbox oil pan.
• Replace the Automatic Transmission Fluid (ATF).
• Perform essential basic settings for the gearbox in the following order:
  • Calibration of clutch valves (-N215, -N216).
  • Calibration of movement sensors (-G487, -G488, -G489, -G490).
  • Clutch engagement point adaptation.

Required Tools and Parts

Technicians will utilize specific tools and follow defined labor operations for this repair:

• Pico NVH tool (VAS 611015): This specialized tool is used with accelerometers (accelerometer 1, 2, 3) and microphones for noise analysis. The setup time for this tool is covered under diagnostic time code 0161 0000.
• Service Numbers: Dual Clutch Replacement: 3060, Bearing A replacement: 3059.
• Damage Codes: Dual Clutch Replacement: 0010, Bearing A replacement: 0015.
• Labor Operations:
  • Remove and install gearbox: 3435 19xx (with associated operations).
  • Remove and install multiple clutch: 3060 19xx (with associated operations).
  • Replace input shaft bearing: 3545 5599 (billed according to time required).
  • Replace (all) oil filters (includes remove, install, and clean mechatronic unit): 3488 5599 (190 Time Units).
  • Gearbox oil pan (replace magnet): 3460 5599 (10 Time Units).
  • Check bearing (take photo of bearing): 3546 0199 (10 Time Units).
• Diagnostic Times: Guided Fault Finding (GFF): 0150 0060; Set-up time for noise analysis tool: 0161 0000; Charge battery: 2706 8950.

Important Warnings and Recommendations

Audi has provided critical instructions for technicians to ensure proper repair and warranty coverage. Owners should be aware of these points:

• Warranty Claim Rejection: "If the documentation of the test steps is incomplete (e.g. without photos), the warranty claim may be rejected." It is crucial for technicians to provide thorough photographic evidence.
• Strict Repair Criteria: "The following repair must only be carried out if all the criteria (model/type, chassis number, engine/gearbox code, PR number(s), part number, software version, code etc.) apply exactly. Otherwise, this measure will not eliminate the problem, and repeat repairs may be necessary. In such a case, we may reject the warranty claim and charge back the cost of the parts." This emphasizes the importance of precise diagnosis before proceeding with repairs for the Audi A6 transmission noises.
• Learnt Values: "Do not delete any learnt values for the gearbox!" This prevents loss of critical transmission adaptation data.
• Guided Fault Finding (GFF) Test Plans: "Do not complete the test plans of the Guided Fault Finding for: Replacing gearbox; replacing mechatronic unit; and/or replacing valve body." Technicians should avoid these specific GFF test plans as part of this measure.
• Software Updates: "Do not update the gearbox software as part of this measure." Software updates are not part of this specific repair procedure.
• Technical Repair Query: "A technical repair query is not necessary." This indicates that the TSB provides sufficient guidance for the repair.

Warranty Information

Warranty claims for this issue must adhere to the Audi Warranty Policies and Procedures Manual. All claims are subject to review or audit by Audi Warranty. If the vehicle is outside of its warranty period, this Technical Service Bulletin is for informational purposes only, and any repairs would typically be at the owner's expense. The TSB specifies various claim types, service numbers, damage codes, and labor operations for technicians to use when submitting warranty claims.

NHTSA ID: 11018975