2022-2023 Audi Models Rear Suspension Rattle TSB

Owners of 2022-2023 Audi models may experience an Audi e-tron rear suspension rattle or similar noises from the rear of their vehicle. This issue is detailed in Technical Service Bulletin (TSB) 42 22 48 2038689/6, which outlines a procedure to resolve clunking or rattling sounds originating from the rear suspension.

Symptoms

If your vehicle is affected by this issue, you will most likely notice:

• "Clunking or rattling noises are heard from the rear suspension area when the vehicle is driven over bumps."

This Audi e-tron rear suspension rattle can be particularly noticeable when driving over uneven surfaces or speed bumps.

Technical Background

The root cause of the clunking or rattling noise is an improperly seated rear bump stop. This often occurs if the rear bump stop was not fully inserted into the rear shock absorber mounting during the Pre-Delivery Inspection (PDI) process at the dealership. To address this, a specialized bump stop installation tool, SET900, was developed to ensure proper seating.

Repair Procedure Summary

To correct the improperly seated rear bump stop and eliminate the Audi e-tron rear suspension rattle, technicians will perform the following steps:

1. Preparation: The top of the rear bump stops will be cleaned and coated with tire mounting paste to aid in installation.
2. Installation: The SET900 special tool (Figure 1 and Figure 2 in the TSB) will be used to fully press the rear bump stops into the upper shock mounts. This tool provides the necessary leverage to correctly seat the bump stops, preventing them from dislodging and causing noise (Figure 3 in the TSB).
3. Inspection and Replacement: If the bump stops were damaged during vehicle transport, technicians will attempt to reshape them by warming them slightly. If reshaping is not possible, the affected components will be replaced.

Required Tools or Parts

Dealers will use specific items to perform this repair:

• Tool Number: SET900 (Bump stop installation tool)
• Part Number (from ETKA): Buffer Stop
• Part Number (from ETKA): Fasteners, Bolts, Nuts, and Screws (as needed per the Repair Manual)

Additional information regarding viewing TSB videos, including a video demonstrating the use of the SET900 tool, can be found in TSB 2039206.

Warranty Information

This repair is covered under warranty for vehicles up to 48 months or 50,000 miles, whichever comes first. The Service Number for this procedure is 4298, and the Damage Code is 0020. Various labor operations are specified depending on whether one or two bump stops are secured or replaced, with diagnostic and road test times also allocated. The claim comment for this procedure is "As per TSB 2038689/6."

What Owners Should Know

It is important to note that if your vehicle is outside of the specified warranty period (48 months/50,000 miles), this Technical Service Bulletin is for informational purposes only, and the repair costs may not be covered. Always check with your authorized Audi dealer for the most accurate information regarding your vehicle's warranty status and potential repair costs.

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Source: NHTSA ID: 10209245