2022-2024 Audi Roof Corrosion TSB 2068999/1

Symptoms of Roof Corrosion

Owners of affected Audi vehicles, including the 2023 Audi Q8, may observe a "Visible corrosion at joint between roof and roof side member." This typically appears as a visible line of corrosion forming in the roof, specifically along the right or left roof channel seams. Workshop findings confirm this corrosion often forms under what appear to be cracks in the top coat of the paint.

Understanding the Cause

Audi Technical Service Bulletin 2068999/1 explains that this corrosion likely originates from underlying metal being exposed and unprotected due to cracks in the paint's top coat. These paint cracks in the roof channel seams can be caused by external impacts, such as heavy snow loads, contact with cargo carriers, or hail storms. Even microscopic cracks, if left unrepaired according to Audi's collision repair guidelines, can lead to corrosion over time. Repairs like paintless dent removal may also leave subtle waviness in the roof panel, potentially masking unaddressed paint cracks that leave the metal vulnerable.

Diagnostic Procedure

To properly assess the "Visible corrosion at joint between roof and roof side member," Audi technicians follow a detailed diagnostic process:

1. Visual Inspection: The initial step involves confirming the presence of corrosion and identifying any associated paint cracks. These cracks may require viewing under magnification for detection.
2. Impact Assessment: Technicians carefully examine the roof panel for any evidence of external impact. This includes looking for a characteristic waviness in the roof panel, which might only be visible with careful examination using a contrasting pattern or appropriate backlighting and reflective patterns.
3. Paint Thickness Measurement: The paint thickness is measured at several points on both sides of the roof panel. The ideal paint thickness range for the roof panel is specified as between 3.5 mm and 5.4 mm.
4. Internal Inspection: If roof deformation cannot be detected externally but the paint cracks are consistent with the condition described in TSB 2068999/1, it may be necessary to remove the headliner to examine the inside of the roof panel for persistent deformation.

Important Warnings for Owners

Audi Technical Service Bulletin 2068999/1 states that this TSB is informational only and not applicable to any Audi warranty. This means that any repairs related to this type of corrosion, particularly if attributed to external impact, may not be covered under your vehicle's warranty. Prior to any repair, extensive documentation and a consultation with an Audi After Sales Service Manager (AASM) are required before any warranty application can even be considered.

What Owners Should Do

If you observe "Visible corrosion at joint between roof and roof side member" on your 2022-2024 Audi vehicle, including your 2023 Audi Q8, it is crucial to contact an authorized Audi dealer. They will perform the necessary diagnostic steps, including thorough photo and video documentation of the roof structure, paint inspection, and paint thickness measurements. This documentation will be submitted to DocIT. If no evidence of external impact is found, your AASM must be contacted before any repair. All paint and corrosion cases require on-site inspection by an AASM for warranty determination, with a field representative corroborating the documentation before a final decision is made by Audi Warranty and Product Support.

Source: NHTSA ID: 10230641, Manufacturer Communication Number: 2068999/1