What is TSB 51 20 16 2060145/2 about?

TSB 51 20 16 2060145/2 addresses cracking or snapping noises originating from the right rear roof area of 2021 Audi Q8, SQ8, and RS Q8 vehicles, particularly during steering maneuvers or body flex.

What causes the cracking noises in the Audi Q8's roof?

The cracking noises are caused by structural tolerances between the roof panel and the roof support sheet metal, which allow for intermittent movement and noise generation when the vehicle's body flexes.

Is the repair for the 2021 Audi Q8 cracking noises covered under warranty?

Yes, the repair is covered under Audi's warranty for up to 48 months or 50,000 miles, whichever comes first. If your vehicle is outside this warranty period, the TSB serves as informational guidance.

What is the repair procedure for the roof noise?

The repair involves removing the headliner and sunroof assembly, drilling a precise 10 mm hole in the roof structure (not exceeding 3 mm depth), and then injecting a specialized 2K insert foam (part numbers D 506KD1A3 or D 506KD1A4) into the affected cavities to stabilize the structure.

Audi Q8/SQ8/RSQ8 Cracking Noises TSB 51 20 16 2060145/2

Owners of 2021 Audi Q8, SQ8, and RS Q8 vehicles may notice unusual cracking or snapping noises coming from the right rear roof area, particularly during steering thrusts or when the vehicle body flexes. This issue is addressed by Audi Technical Service Bulletin (TSB) 51 20 16 2060145/2, which supersedes an earlier bulletin, 20-14, dated July 24, 2020.

Symptoms

Customers typically report hearing a distinct noise in the right rear roof area of the cabin. This noise is most noticeable with abrupt steering input or when the vehicle's body flexes. The sound is often described as a "cracking" or "snap" type of noise. If you experience these 2021 Audi Q8 cracking noises, it's important to have your vehicle inspected.

Diagnosis / Trigger Conditions

For technicians to accurately diagnose this issue, the noise must be reproducible. Audi advises that if the symptom cannot be duplicated during a test drive with the customer, the repair outlined in TSB 51 20 16 2060145/2 should not be performed. The noise's type and location must clearly match the description in the TSB, specifically originating from the right rear-most area of the sunroof opening within the roof structure.

Technical Background

The root cause of the 2021 Audi Q8 cracking noises stems from the structural tolerances between the roof panel and the roof support sheet metal. These tolerances can allow for intermittent movement, generating the cracking or snapping sounds when the vehicle's body experiences flexing, such as during sharp steering maneuvers.

Important Warnings

Do not perform the repair outlined in TSB 51 20 16 2060145/2 if the noise symptom cannot be duplicated during a test drive with the customer.
When drilling, the penetration depth must not exceed 3 mm. Exceeding this depth can cause irreparable damage to the roof structure, requiring its replacement.
When injecting foam, do not exceed 1 full second of trigger pulse per fill, as injecting too much foam can lead to excessive volume.

Repair Procedure Summary

The repair for the 2021 Audi Q8 cracking noises involves injecting a specialized foam into specific areas of the roof structure. The procedure includes:

Preparation: The headliner and sliding sunroof assembly are removed to access the affected area in the rear of the sunroof opening, starting with the right rear. The procedure must also be performed on the corresponding left rear-most area.
Drilling: A 10 mm diameter hole is drilled in a specific spot within the roof structure. Technicians must use a drill bit depth stop to ensure the penetration does not exceed 3 mm. Care must be taken to contain drilling shavings.
Foam Preparation: A 2K insert foam (part numbers D 506KD1A3 or D 506KD1A4) is prepared by shaking the can for two minutes plus an additional 20 shakes to ensure a homogenized mixture.
Foam Injection: The foam canister must be held vertically with the nozzle pointing down. Before injection, the nozzle and tube are purged of air. Foam is then injected into the cavity by inserting the hose in two directions (labeled 'B' and 'A' in the TSB's figures) for one full second of trigger activation per direction. This fills the cavity with the appropriate volume of foam.
Curing and Reassembly: The foam is allowed to cure for 12 hours. After curing, the headliner and sunroof assembly are reinstalled. Technicians must remember to set the sunroof panel and rollershade end stop adaptation after reassembly, referring to TSB 2054505 for instructions regarding sunroof operation.
Verification: A thorough test drive is performed to ensure the noises have been eliminated.

Required Tools or Parts

To perform this repair, the following parts are necessary:

2K-Insert Foam: D 506KD1A3 or D 506KD1A4 (Quantity: 01)
Fasteners, bolts, nuts, and screws as needed per the repair manual.

Warranty Information

This repair is covered under Audi's warranty for up to 48 months or 50,000 miles, whichever comes first. If the vehicle is outside of warranty, this Technical Service Bulletin serves as informational guidance only. The claim type is 110. Labor operations include:

Headliner remove and reinstall (7084 1900)
Sunroof frame remove and reinstall (6028 1950)
Perform roof rework (5103 9999) – 30 Time Units (TU)
Road test prior to service (0121 0002) – 10 TU
Road test after service (0121 0004) – 10 TU

Diagnostic time (GFF) is not allowed. All warranty claims must adhere to the Audi Warranty Policies and Procedures Manual.

Owner Action

If your 2021 Audi Q8, SQ8, or RS Q8 is exhibiting cracking or snapping noises from the right rear roof area, contact your authorized Audi dealership. Describe the symptoms clearly, noting when the 2021 Audi Q8 cracking noises occur. The dealership will be able to diagnose the issue and perform the necessary repair as outlined in TSB 51 20 16 2060145/2.

NHTSA ID: 10181768