2021-2022 Audi Door Handle Binding TSB 2060196/3

Owners of certain 2021-2022 Audi vehicles, including the 2022 Audi Q8, may experience issues with their exterior door handles. This Technical Service Bulletin (TSB) 57 21 80 2060196/3, dated July 26, 2021, outlines a repair procedure for door handles that are binding or not returning to the zero position. This TSB supersedes an earlier bulletin, 20-71, issued on July 24, 2020.

Symptoms

Customers may report several issues related to the door handle binding. These include:

• "Central locking and/or door open warnings displayed in the instrument cluster."
• "The doors are not closing and/or locking properly."
• "The door handles are binding and protruding."

Workshop findings confirm that the exterior door handles are binding and fail to return to their normal, flush position.

Technical Background

The root cause of the problem is attributed to material tolerances. Specifically, the door handle guide can bind within the door handle mounting bracket, preventing the handle from moving freely and returning to its zero position. Audi has implemented improved parts in production to address this issue in newer vehicles.

Repair Procedure Summary

The repair for the 2022 Audi Q8 door handle binding involves a multi-step process to modify the existing door handle components and replace a specific guide piece. The general steps are:

1. Initial Check: Verify the function of all door handles to confirm they do not bind or jam and return to the zero position (as shown in Figure 1 of the TSB). If the door handles are binding and not returning to the zero position, proceed with the repair.
2. Handle Removal: Remove any affected exterior door handles by following the specific instructions in the Elsa Repair Manuals.
3. Rib Modification (Pliers): Using precision diagonal cutting pliers, remove two specific ribs (rib #1 and rib #2) located on the pivot side of the mounting bracket, towards the front of the vehicle (illustrated in Figure 2).
4. Surface Smoothing: After removing the ribs, ensure the resulting surface is smooth and free of any protrusions (as depicted in Figure 3).
5. Rib Modification (Scraping & Sanding): Measure the dimension from the bottom edge of the door handle to the top of rib #3 using a vernier caliper (Figure 4). Scrape the top of rib #3 with a precision/utility knife until the dimension reaches approximately 20.9 mm (0.82 inches) (Figure 5). Further sand down the top surface of rib #3 with sanding paper until the measurement is approximately 20.6 mm (0.81 inches) (Figure 6).
6. Guide Piece Replacement: Replace the door handle guide piece located on the lock cylinder side, towards the back of the vehicle, with a new guide piece (Figure 7). The part number for this component is 4N0837259.
7. Reinstallation & Verification: Reinstall all door handles according to the Elsa Repair Manuals and verify that they function normally, returning to the zero position without binding.

Required Tools or Parts

Technicians will need several specialized tools and a specific part to perform this repair:

• Precision diagonal cutting pliers
• Vernier caliper
• Precision/utility knife
• Sanding paper
• Fasteners, Bolts, Nuts, and Screws: As needed, per the ETKA and Repair Manuals.
• Guide Piece: Part number 4N0837259 (01-04 pieces, as needed).

Warranty Information

This repair is covered under warranty for vehicles up to 48 months or 50,000 miles. For Certified Pre-Owned (CPO) vehicles, the claim type is G10, requiring owner verification. If the vehicle falls outside of any warranty, this Technical Service Bulletin serves as informational guidance only.

• Claim Type: 110 (up to 48 Months/50,000 Miles) or G10 (for CPO Covered Vehicles – Verify Owner).
• Service Numbers: 5711, 5811.
• Damage Code: 0017 (for left 001 and/or right 002 door handles).
• Claim Comment: As per TSB #2060196/3.

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Source: NHTSA ID: 10199723