2022-2023 Audi Brake Disc Corrosion TSB

Owners of 2022-2023 Audi vehicles may encounter issues related to Audi brake disc corrosion, manifesting as visible rust layers or unusual noises during braking. This Technical Service Bulletin (TSB) 2067132/1, issued on May 23, 2022, provides guidance for technicians on diagnosing and addressing these concerns.

Symptoms

Customers may report the following conditions:

• A visible "Rust layer on the brake disc."
• "Noises and/or vibrations when braking."

Upon inspection, the workshop should be able to confirm these complaints.

Technical Background

Understanding the underlying causes of Audi brake disc corrosion is crucial for effective diagnosis and prevention. Corrosion on the friction surface of steel brake discs can occur due to several factors:

• Environmental Exposure: Moisture and road salt significantly contribute to corrosion, especially if the vehicle is stationary for extended periods.
• Braking Habits: Light use of the brakes during short journeys can lead to insufficient brake cleaning, allowing rust to accumulate.
• Material Properties: The brake disc material, identified as "flake graphite cast iron," is inherently not resistant to corrosion.
• Design Limitations: It is not possible to apply an anti-corrosion coating directly to the friction surfaces of the brake disc.

Brake discs are constantly exposed to environmental influences such as water, salt, snow, and dirt, making them susceptible to these issues.

Diagnosis and Repair Procedure Summary

If you are experiencing symptoms of Audi brake disc corrosion, an authorized Audi service center will perform a specific diagnostic and repair procedure:

1. Extensive Test Drive: Technicians will conduct an extensive test drive involving several brake operations to assess the condition.
2. ABS Stops: With careful consideration of traffic conditions, 2-3 ABS stops will be performed from speeds above 50 mph. It is critical to allow brake components to cool by driving the vehicle for more than one minute at speeds greater than 50 mph between each stop.
3. Pad Contact Check: The technician will check that the brake pads make correct contact with the disc, ensuring they are cleaning the entire surface of the brake disc.
4. Component Replacement: If the rust layer or noises persist and the condition is not eliminated after the test drive and cleaning attempts, the brake disc and pads will be replaced.

Important Warnings

Owners and technicians should be aware of the following critical information:

• New Pads/Discs: "Do not perform ABS stops if brand new pads and/or discs are installed." This is crucial to prevent damage or improper bedding of new components.
• Warranty Coverage: This TSB is informational only and is "not applicable to any Audi Warranty." Owners should be prepared for potential costs associated with diagnosis and repair.

Owner Action

If you observe a rust layer on your brake discs or experience noises and vibrations when braking, it is recommended to contact your local authorized Audi service center. They can perform the necessary diagnostic procedures outlined in TSB 2067132/1 to determine the cause and recommend appropriate action.

Source: NHTSA ID 10212144