2018-2023 Audi Models Outer Door Seal Detachment TSB

Symptoms of a Detached Outer Door Seal

Audi owners may notice that the outer door seal has come loose or is detached from the door. This issue is specifically noted as "bonded outer door seal is detached from the door" in Technical Service Bulletin (TSB) 2064183/5. The detachment can occur in any area where the outer door seal makes contact with the door.

Technical Background

According to Audi, the detachment of the outer door seal is influenced by several factors. These include pressure, temperature fluctuations, and contamination in the bonding area. These conditions can compromise the adhesive bond between the outer door seal and the door frame, leading to the seal coming loose. This technical background helps explain why the Audi e-tron door seal detached problem might occur.

Important Warnings for Repair

Audi has provided specific instructions and warnings for technicians performing this repair to ensure proper adhesion and prevent recurrence:

• "Do not stretch the seal during installation." Stretching the seal can lead to improper fitment and future detachment.
• "To prevent the outer door seal from becoming detached or misaligned, the door must not be closed for at least 30 minutes." This allows the bonding agent sufficient time to cure.

Repair Procedure Summary

The repair for a detached outer door seal involves replacing the affected door seals according to detailed instructions found in the Elsa repair manual. Technicians will follow specific paths depending on the door location:

• Front Doors: Refer to "Elsa>>Repair manual>>Body>>Body Exterior>>57 Front Doors, Central Locking System>>Door>>Outer Door Seal, Removing and Installing".
• Rear Doors: Refer to "Elsa>>Repair manual>>Body>>Body Exterior>>58 Rear Doors>>Door>>Outer Door Seal, Removing and Installing".

Key steps in the repair process include:

1. Preparation: Ensure both the vehicle and the new seal are at room temperature. The bonding surfaces on the door must be thoroughly cleaned and free of dirt and grease.
2. Adhesive Removal: Any remaining adhesive tape from the previous seal must be removed using adhesive strip remover VAS 6349.
3. Surface Cleaning: The painted bonding surface must be cleaned with cleaning solution D 009 401 04 and allowed to dry completely before applying the new seal.
4. Installation: When positioning the new outer door seal, technicians are advised to use the routing of the outer door seal on the opposite, unaffected side as a guide. It is crucial not to stretch the seal during installation.
5. Curing: After installation, the door must remain open for at least 30 minutes to allow the bonding agent to set properly and prevent the seal from becoming detached or misaligned.

This meticulous process ensures that the Audi e-tron door seal detached issue is resolved effectively.

Required Tools and Parts

To perform this repair, specific parts and tools are required:

• All-purpose cleaner: D00940104
• Bonding agent: D355205A2
• Applicator: D00950025
• Adhesive strip remover: VAS 6349 (or equivalent)
• Roller: T40400 (or equivalent)
• Fasteners, Bolts, Nuts, and Screws: As needed, referenced in ETKA/ELSA.

Technicians should always check with their Parts Department and ETKA for the latest information and parts bulletins.

Warranty Information

This Technical Service Bulletin outlines warranty claim procedures for the outer door seal detachment.

• Claim Type: Warranty claim type 110 applies for vehicles up to 48 months or 50,000 miles. For Audi Certified Pre-Owned (CPO) vehicles, claim type G10 is used, requiring owner verification.
• Out of Warranty: If the vehicle is outside of any applicable warranty, this TSB serves as informational guidance only, meaning the repair may not be covered.
• Service Numbers:
  • Front door seal: 5765
  • Rear door seal: 5864
• Damage Codes:
  • 0010
  • 0018 (specifically for A5 models)
• Labor Operations: Specific labor operation codes are provided for different models and repair scenarios:
  • Outer front door seal remove + reinstall:
    • 5765 1950 (Audi e-tron models)
    • 5765 5500 (A3)
    • 5765 1900 (Q8, A5)
  • Two outer front door seals remove + reinstall: 5765 2099 (A5) (100 Time Units)
  • Rear door outer seal remove + reinstall:
    • 5864 1900 (Audi e-tron models, Q8, A5)
    • 5864 5500 (A3)
  • Two rear door outer seals remove + reinstall: 5864 2099 (A5) (120 Time Units)
• Diagnostic Time: "GFF" is listed with "No allowance" for diagnostic time. Road tests prior to and after the service procedure also have "No allowance" for time.
• Claim Comment: All warranty claims must include the comment "As per TSB 2064183/5" and adhere to the Audi Warranty Policies and Procedures Manual. Claims are subject to review and audit by Audi Warranty.

Revision History

Technical Service Bulletin 57 23 07 2064183/5, issued on May 19, 2023, supersedes an earlier version, TSB Group 57 number 22-96, dated September 22, 2022. Previous revisions include:

• Revision 5 (May 19, 2023): Revised header (added models), revised warranty information (damage code, labor operations), and revised required parts and tools.
• Revision 4 (September 22, 2022): Revised header (added models), revised service information (added repair manual path), and revised warranty information (labor operations).
• Revision 3 (December 22, 2021): Revised header (added models) and revised warranty information (labor operations).

Source: NHTSA ID 10236621