2022-2023 Audi Models Brake Noise TSB

Owners of 2022-2023 Audi models, including the Audi e-tron, may experience various types of brake noise. Audi Technical Service Bulletin (TSB) 2034181/22, issued on August 11, 2022, provides comprehensive guidance for diagnosing and addressing these concerns. This bulletin supersedes an earlier version, Group 46 number 22-32, dated June 3, 2022.

Symptoms

Customers may report hearing brake noise from either the front or rear brakes. This Audi e-tron brake noise can manifest in several ways:

• "squealing"
• "squeaking"
• "grinding"
• "groaning"
• "thumping"
• "creaking"

Important Warnings

Audi advises technicians and owners of critical information regarding this TSB:

• DO NOT use this TSB if there is another brake noise TSB specifically applicable to your vehicle's VIN. Always refer to the Audi Brake systems brochure for additional information.
• DO NOT alter the brake pads when performing the cleaning procedure outlined in this bulletin.

Technical Background: Causes of Brake Noise

Brake noise, including the Audi e-tron brake noise, can stem from several common issues. The TSB identifies the following primary causes:

1. Wear Limit: Brake discs or pads are nearing or have reached their wear limit.
2. Improper Embedding: New brake pads and/or discs were not properly embedded after installation.
3. Aftermarket Parts: Installation of non-OEM aftermarket pads or discs.
4. Debris: Presence of debris, such as small stones, grit, road salt, or sand, between the brake disc and brake pad.
5. Rust on Discs: Discs are covered with rust, which can form if the vehicle has been parked for an extended period, especially in wet conditions (as shown in Figure 1 of the TSB).
6. Grooved Discs: The brake discs have developed grooves (illustrated in Figure 2 of the TSB).
7. Chemical Contamination: Chemical contamination on the braking surface, often from wheel or tire cleaner being sprayed directly onto the brake disc (Figures 3 and 4 of the TSB).
8. Pad Marks: "Pad marks" on the brake disc due to brake pad material transferring to the discs. This can occur when the vehicle is parked for long periods in wet or snowy environments (Figure 5 of the TSB).

Diagnosis and Repair Procedure Summary

To address the Audi e-tron brake noise, technicians should follow a structured diagnostic and repair process:

1. Check Brake Condition: First, assess the overall condition of the brakes to determine if the noise is caused by one of the issues listed in the technical background. If the noise is not attributed to these causes, proceed to the next steps.
2. Locate Noise: Pinpoint the exact location of the brake noise (e.g., left front, front axle, rear axle). An assistant listening from inside or outside the vehicle may be necessary for accurate identification.
3. Record Sound and Questionnaire: Obtain a sound or video recording of the noise. Sound recordings should ideally be made using the Audi analysis app (refer to TSB 2051095: 46 Audi frequency analysis). Recordings submitted by customers are also acceptable. Fill out the accompanying questionnaire with as much detail as possible.
4. Clean Brake Pads and Discs: This is a multi-step process:
   • ABS Stops: Perform up to 5 ABS stops from speeds above 50 mph, allowing brake components to cool for over a minute at speeds greater than 50 mph between each stop.
   • Cool Down: Allow the vehicle to sit for two hours to cool down completely.
   • Manual Cleaning: Manually clean all brake components, removing dust from springs, retaining clips, pistons, calipers, and pins. Clean all contact points between pads/clips/caliper and apply the correct lubrication paste (refer to ELSA for specific application details).
   • Test Drive: Test drive the vehicle again. If the noise persists, open a Technical Assistance Center (TAC) ticket, including the completed Brakes Acoustic Questionnaire, sound/video recordings, and a frequency analysis screenshot (Figure 6 of the TSB).

Known Brake Noise Frequencies and Repair Suggestions

The TSB also provides specific repair suggestions based on the brake system type and the frequency of the noise. This information serves as a reference, and technicians should always consult the ELSA Repair Manual for vehicle-specific repair details.

• Brake system ATE-TEVES (PR codes: 1LF, 1LG, 1LL, 1ZK, 1LJ, 1LP):
  • 1.6 KHz from front brakes: Inspect front pads.
  • 3.2 KHz/11 KHz from front brakes: Inspect front discs and pads.
• Brake system TRW (PR codes: 1LA, 1LB, 1LD, 1LT, 1ZT, 1LJ):
  • 1.6 KHz to 1.7 KHz from front brakes: Inspect front discs.
  • 3.2 KHz from front brakes: Inspect, clean, and lubricate guide pins in the caliper carrier using anti-seize paste G052560A2.
  • 7.8 KHz from front brakes: Inspect front pads.

Required Tools or Parts

For specific repair steps, the TSB mentions:

• Anti-seize paste G052560A2 for lubricating guide pins in TRW brake systems.

Warranty Information

This TSB outlines warranty claim procedures for addressing Audi e-tron brake noise:

• Claim Type: Applicable for vehicles up to 12 months/12,000 miles. If the vehicle is outside warranty, this TSB is for informational purposes only.
• Service Number: 4617
• Damage Code: 0020
• Labor Operations: Cleaning brake pads and discs (4617 8099, 50 TU). This includes road tests, audio file submission, and questionnaire completion.
• Diagnostic Time: GFF (No allowance, 0 TU), Road test prior to service (No allowance, 0 TU), Road test after service (No allowance, 0 TU).
• Claim Comment: As per TSB 2034181/22.

All warranty claims must adhere to the Audi Warranty Policies and Procedures Manual and are subject to review.

Additional Information

Two other Technical Service Bulletins may be necessary to complete this procedure:

• TSB 2022584: 46 Brake pulsation diagnostic guidelines.
• TSB 2051095: 46 Audi frequency analysis.