2020-2026 Audi Rear Suspension Rattle TSB

Symptoms

Owners of 2020-2026 Audi vehicles may notice a specific sound coming from the rear of their car. The primary symptom described is "Clunking or rattling noises are heard from the rear suspension area when the vehicle is driven over bumps."

Technical Background

This persistent "Audi e-tron rear suspension rattle" is often attributed to an improperly seated rear bump stop. This occurs when the rear bump stop was not fully inserted into the rear shock absorber mounting during the Pre-Delivery Inspection (PDI) process. To address this, Audi developed a specialized bump stop installation tool, the SET900, to ensure proper seating of the rear bump stop in the shock absorber mounting.

Repair Procedure Summary

To resolve the 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 facilitate installation.
2. Installation: The SET900 special tool is used to fully press the rear bump stops into the upper shock mounts. This tool provides the necessary leverage to properly seat the bump stops, preventing them from dislodging and causing noise. Figure 2 in the TSB illustrates the SET900 tool in use, while Figure 3 provides a comparison of bump stop installation with and without the tool.
3. Dust Boot Check: Technicians must ensure that the dust boot does not get caught on the top of the shock once the vehicle is lowered.
4. Buffer Stop Inspection: If the buffer stops show signs of damage from vehicle transport, technicians may attempt to reshape them by warming them up slightly. If this is not possible, the affected components must be replaced.

Audi provides a video demonstrating the use of the SET900 tool, accessible via a QR code (Figure 4) or directly through the link: https://audi-external.kzoplatform.com:443/swf/player/286. Further information on viewing TSB videos is available in TSB 2039206.

Required Tools or Parts

To perform this repair, specific tools and parts may be necessary:

• SET900: This is the specialized bump stop installation tool.
• Buffer Stop: If the existing buffer stops are damaged and cannot be reshaped, new ones will be required (Part Number: See ETKA).
• Fasteners, Bolts, Nuts, and Screws: As needed per the repair manual (Part Number: See ETKA).

Warranty Information

This Technical Service Bulletin (TSB 2038689/7) outlines the warranty coverage for this repair. It is generally covered for up to 48 months or 50,000 miles, whichever comes first. If your vehicle is outside of this warranty period, the TSB serves as informational guidance only.

Dealers will use Service Number 4298 and Damage Code 0020 for warranty claims. Labor operations include:

• Secure rear axle buffer stop: 4298 1399 (10 TU)
• Secure two rear axle buffer stops: 4298 1499 (20 TU)
• Replace rear axle buffer stop: 4298 5599 (90 TU)
• Replace rear axle buffer stop (Magnetic Ride): 4298 5599 (100 TU)
• Replace two rear axle buffer stops: 4298 5699 (140 TU)
• Replace two rear axle buffer stops (Magnetic Ride): 4298 5699 (160 TU)

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

Source: NHTSA ID: 10241421