2021-2025 Audi DL382 Transmission Noises TSB

Audi has issued Technical Service Bulletin (TSB) 2074806/4 to address customer concerns regarding Audi DL382 transmission noises and vibrations. This bulletin applies to a range of 2021-2025 Audi models equipped with the DL382 transmission, including the A4, A5, A6, A7, and Q5.

The TSB details diagnostic procedures and repair steps for technicians to identify and resolve the source of these noises, which can occur under various driving conditions or while stationary. The primary focus of the repair involves inspecting and potentially replacing components within the dual clutch assembly.

Symptoms of Audi DL382 Transmission Noises

Owners may experience several symptoms indicating an issue with their DL382 transmission. These include:

• Noises occurring after selecting a gear while the vehicle is idling and stationary.
• Noises present when driving in odd-numbered gears (1st, 3rd, 5th gear).
• Noises present when driving in even-numbered gears (Reverse, 2nd, 4th gear).
• Visible oil loss from the transmission.

Technicians may also observe noises originating from the rear of the gearbox or the area of the dual-mass flywheel. The characteristics of these noises, such as changing with gear selection or engine speed, are important diagnostic indicators.

Diagnosis and Trigger Conditions

To accurately diagnose the source of the Audi DL382 transmission noises, technicians are instructed to reproduce the customer complaint. This involves listening for noises in the vehicle interior and from the gearbox itself. Specialized tools can assist in this process.

Diagnosis may include using a Pico NVH tool (VAS 611015) with accelerometers to pinpoint the source of vibrations and noises. Technicians also perform a visual inspection of the permanent magnets in the oil pan for signs of abrasion, and inspect Bearing A within the dual clutch cover for wear or damage.

Important Warnings for Owners and Technicians

Audi has provided specific instructions to ensure proper diagnosis and repair, and to prevent unnecessary work or warranty claim rejections:

• The repair outlined in TSB 2074806/4 must only be performed if all specified criteria (model, chassis number, engine/gearbox code, PR number(s), part number, software version, etc.) are met exactly. Failure to do so may not resolve the problem and could lead to repeat repairs, potentially resulting in warranty claim rejection and charge-back of parts costs.
• "Do not delete any learnt values for the gearbox!"
• "Do not complete the test plans of the Guided Fault Finding for: Replacing gearbox; replacing mechatronic unit; and/or replacing valve body."
• "Do not update the gearbox software as part of this measure."
• If the documentation of the test steps is incomplete (e.g., without photos), the warranty claim may be rejected.
• A technical repair query is not necessary for this issue.

Repair Procedure Summary

The repair process for Audi DL382 transmission noises involves a detailed inspection and component replacement based on the findings. Technicians must first reproduce the complaint and perform a visual inspection of Bearing A in the dual clutch cover, documenting findings with photos.

Depending on the condition of Bearing A, one of two repair paths is followed:

1. If wear is visible on Bearing A and the ball cage is intact: Replace Bearing A in the dual clutch cover.
2. If the ball cage is no longer in Bearing A or has irreparable damage: Replace the entire dual clutch assembly.

Regardless of which repair path is taken, additional steps are required:

• Replace the high-pressure filter, low-pressure filter, and intake filter.
• Thoroughly clean the valve body area after filter removal.
• Replace the permanent magnets in the gearbox oil pan.
• Replace the Automatic Transmission Fluid (ATF).

After completing these physical repairs, specific basic settings of the gearbox must be performed in order:

• Calibration of clutch valves -N215, -N216.
• Calibration of movement sensors -G487, -G490.
• Clutch engagement point adaptation.

Required Tools and Parts

Technicians will utilize specific tools and components for this repair:

• Pico NVH tool (VAS 611015) for noise and vibration analysis.
• Accelerometers for measurement.
• Replacement high-pressure filter, low-pressure filter, and intake filter.
• New permanent magnets for the gearbox oil pan.
• Fresh Automatic Transmission Fluid (ATF).
• Potentially a new Bearing A or a complete dual clutch assembly, depending on the diagnosis.

Warranty Information

Warranty claims for this issue are subject to review by Audi Warranty and 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.

Relevant service and damage codes for warranty claims include:

• Service Number: Dual Clutch Replacement: 3060, Bearing A replacement: 3059
• Damage Code: Dual Clutch Replacement: 0010, Bearing A replacement: 0015

Labor operations are billed according to specific codes, such as 3435 19xx for removing and installing the gearbox, 3060 19xx for removing and installing the multiple clutch, and 3545 5599 for replacing the input shaft bearing. Diagnostic time for GFF is 0150 0060, and set-up time for the noise analysis tool is 0161 0000.

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NHTSA ID: 11021452