2021-2025 Audi Cracking Noise from Front or Rear End TSB

Audi has released Technical Service Bulletin (TSB) 2061464/9 to address a specific issue affecting various 2021-2025 Audi models. This bulletin, dated January 9, 2025, supersedes an earlier TSB, 24-84, from October 8, 2024, and provides updated information regarding a cracking noise that can be heard from the vehicle's front or rear end.

Symptoms

Owners may notice a distinct Audi cracking noise coming from the vehicle. This noise is typically heard under specific conditions:

• When changing direction, a cracking noise can be heard from the vehicle's front end.
• On quattro vehicles, the cracking noise may also be heard from the rear end.
• When driving the vehicle away from a standstill, a cracking noise which occurs once can be heard from the left or right side of the vehicle's front or rear end after changing direction.

Technical Background

The root cause of this Audi cracking noise has been identified as relative movement of the stub axle of the drive shaft within the wheel bearing. To mitigate this issue in production, Audi gradually introduced optimized stub axle splines in the outer joint.

Important Warning

After the repair procedure involving the drive axle(s) is completed, it is crucial that the vehicle must not be operated for 8 hours. This waiting period allows the bonding agent to properly cure and ensure the integrity of the repair.

Repair Procedure Summary

To resolve the Audi cracking noise, technicians are instructed to bond the stub axle of the drive shaft into the wheel bearing. This procedure involves using a specific locking fluid, part number D 154100A1. Approximately 5 ml of this fluid is required for each drive shaft.

The locking fluid must be applied as two continuous adhesive beads. The first bead is placed where the splines begin, and the second bead is applied at the center of the splines. Technicians will follow detailed instructions provided in the ELSA repair manual, specifically under Chassis >> Suspension, Wheels, Steering >> 40 Front Suspension >> Front Axle >> Drive Axle >> Drive Axle Disassembling, Assembling for the reinstallation of the drive axle.

Required Parts and Tools

The primary part required for this repair is:

• D 154100A1: Locking fluid (approx. 0.2 units per repair, depending on the number of drive shafts).

Fasteners, bolts, nuts, and screws may also be needed as specified in the ETKA parts catalog and the repair manual.

Warranty Information

Warranty claims related to this issue should be submitted in accordance with the Audi Warranty Policies and Procedures Manual. The specific details for claiming this repair under warranty are:

• Service Number: 4041/4221
• Damage Code: 0010
• Claim Comment: As per TSB 2061464/9

Labor operations are defined as follows:

• Bond in 1 front outer driveshaft: Labor Operation 4041 4999 (90 Time Units). This includes removing and installing 1 wheel, removing and installing noise insulation, and detaching/re-attaching a suspension link.
• Bond in 2 front outer driveshafts: Labor Operation 4041 5099 (120 Time Units). This includes removing and installing 2 wheels, removing and installing noise insulation, and detaching/re-attaching 2 suspension links.

Similar labor operations are also specified for the rear axle, including removing and installing wheel hubs with bearings and bonding rear outer drive shafts.

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Source: NHTSA ID: 11013693