2012-2024 Audi Roof and Roof Side Member Corrosion TSB

Audi has issued Technical Service Bulletin (TSB) 51 24 31 2068999/2 to address concerns regarding visible corrosion and cracked paintwork at the joint between the roof and roof side member on a wide range of its vehicles. This TSB, dated September 16, 2024, supersedes an earlier bulletin, 23-26, from January 5, 2023, with revisions made to clarify the condition, technical background, and service statements. This bulletin provides crucial information for diagnosing the root cause of this specific Audi roof corrosion.

Symptoms of Audi Roof Corrosion

Owners may notice "Cracked paintwork with corrosion at joint connecting roof to roof side member." Technicians examining affected vehicles have confirmed "corrosion formation" which typically appears "under what appears to be cracks through the top coat of the paint." This visible corrosion at the roof and roof side member joint is the primary symptom.

Technical Background and Trigger Conditions

The underlying cause of this issue is often external force applied to the roof skin panel. This force can lead to a crack in the paintwork where the roof meets the roof side member. Common sources of such force include impacts from hail, large accumulations of snow, or other external factors. It's important to note that these paint cracks may not be immediately apparent, even after dent removal procedures. This delay in detection can allow a significant period to pass before the corrosion becomes visible, contributing to the "Visible corrosion at joint between roof and roof side member" problem.

Diagnosis Procedure Summary

Audi TSB 51 24 31 2068999/2 outlines several steps for technicians to accurately diagnose the presence and extent of this Audi roof corrosion:

• Paint Thickness Measurement: Technicians should perform paint thickness measurements, as illustrated in Figure 1 of the TSB. This helps identify areas where the paint layer might be compromised.
• Visual Inspection for Cracks: A thorough visual inspection is required to identify "resultant corrosion due to cracks in the paint," as shown in Figure 2.
• Magnified Inspection: For subtle damage, especially in the roof channel seams, magnification may be necessary to detect paint cracking. Figure 3 provides a close-up view of paint cracking in the roof channel seam, and Figure 4 shows paint cracks under magnification.
• Surface Deformation Examination: Technicians should also look for surface deformations that could be caused by external forces, such as large amounts of snow falling off a roof. Figure 5 illustrates how remaining roof deformation might evade a cursory view, and Figure 6 shows how a patterned background can aid in examining the roof panel for deformation.

Important Warnings

This Technical Service Bulletin is "informational only and not applicable to any Audi Warranty." Owners should be aware that this document primarily serves to guide technicians in identifying the issue rather than providing a repair procedure covered under standard warranty.

Additional Information

All part and service references within this TSB (2068999) are subject to change. Technicians are advised to consult the Parts Department, ETKA, and the Repair Manual for the most current information regarding parts bulletins and replacement requirements for fasteners, bolts, nuts, and screws.

Source: NHTSA ID 11009365