2021-2024 Audi Q5 e / A7 e Gearbox Malfunction TSB

Owners of 2021-2024 Audi Q5 e and A7 e plug-in hybrid electric vehicles (PHEV) may encounter a 'Gearbox malfunction message' displayed in the instrument cluster. This warning is typically accompanied by a specific diagnostic trouble code (DTC) indicating an internal transmission issue. Audi has issued Technical Service Bulletin (TSB) 2070965/4 to address this concern, providing a software-based solution.

This TSB, identified as 2070965/4, supersedes previous bulletin Group 93 number 24-85 dated July 27, 2024. It outlines the necessary steps for technicians to diagnose and repair the underlying cause of the Audi P288200 gearbox malfunction.

Symptoms

The primary symptom reported by owners is the appearance of a "Gearbox malfunction message" in the instrument cluster. This message indicates a problem with the vehicle's transmission system, specifically related to the power transmission and engine disconnect clutch.

Fault Codes / DTCs

When diagnosing this issue, technicians will typically find the following Diagnostic Trouble Code (DTC) stored in the Transmission Control Module (TCM), designated as -J217- (address word 0002):

• DTC P288200: Engine Disconnect Clutch Excessive Slippage with Symptom code 20954.

Diagnosis / Trigger Conditions

The root cause of the Audi P288200 gearbox malfunction is identified as a software error within the transmission control module. This error can lead to the engine disconnect clutch experiencing excessive slippage, triggering the warning message and DTC. Audi has implemented modified software for the gearbox control unit in series production vehicles starting from model year 2023.

Diagnosis involves checking for the stored DTC P288200. If this code is present, the repair procedure outlined in TSB 2070965/4 should be followed. If the Guided Fault Finding (GFF) system does not detect any faults after the software update, component replacement is generally not necessary.

Important Warnings

Audi has provided critical warnings for technicians during the repair process to ensure safety and prevent damage:

• "To prevent the high-voltage battery from charging during the software update, the high-voltage charging cable on vehicles with high-voltage components must be unplugged BEFORE the SVM code is entered. Charging the high-voltage battery during a software update can cause damage to the high-voltage components."
• "The parking brake must be released, and the diagnostic interface must be hardwired to the scan tool."

Owners should also be aware that "If the vehicle is outside any warranty, this Technical Service Bulletin is informational only." This means that repair costs may not be covered if the vehicle is no longer under warranty.

Repair Procedure Summary

The repair for the Audi P288200 gearbox malfunction primarily involves updating the software of the Transmission Control Module (TCM) and performing subsequent checks. The general procedure is as follows:

1. Software Version Management (SVM) Update: Technicians must follow the instructions in TSB 2011732 for SVM operating instructions. The TCM (-J217-) is updated using the SVM action code 02A220. If the message ER0203E appears during this process, it indicates the gearbox control unit already has the required software version (New Software Part Number 80A927156D, Version 0003 or higher, from Old Software Part Number 80A927156D, Version 0002).
2. High-Voltage Battery Check: The charge level of the high-voltage battery must be between 35% and 90%. If below 35%, it must be charged to a sufficient level.
3. Guided Fault Finding (GFF): If the software update does not resolve the issue, technicians will use GFF to follow the test plan for the DTC memory entry precisely.
4. Additional Checks (if GFF finds no faults): If GFF does not detect any faults, but the issue persists or GFF is not possible, the following checks are performed:
   • Check and adjust the gearbox ATF (Automatic Transmission Fluid) level as per the repair manual.
   • Perform a hydraulic test.
   • Execute the basic settings "calibration of disengagement clutch K0" routine, also known as "Touch point adaptation of hydraulic clutch."

If these steps are completed and no further malfunctions are indicated, the repair procedure is considered complete.

Required Tools or Parts

For this repair, specific parts and tools may be required, depending on the diagnostic findings:

• Dual clutch gearbox oil ATF: Part number G 055 529 A2 (only if needed, quantity as per repair manual).
• Fasteners, Bolts, Nuts and Screws: As needed per the Repair Manual (See ETKA).

Always consult with your Parts Department and/or ETKA for the latest information and parts bulletins.

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Source: NHTSA ID 11007279