2021-2025 Audi Front Suspension Rumbling/Knocking Noise TSB

Owners of certain 2021-2025 Audi Q5, Q7, and Q8 models may experience an unsettling rumbling or knocking noise emanating from the front suspension. This issue, which often becomes noticeable when driving on uneven surfaces, is addressed by Audi Technical Service Bulletin (TSB) 40 25 94 2059996/5. This bulletin provides guidance for technicians to diagnose and resolve the Audi front suspension noise.

Symptoms

If you own a 2021-2025 Audi Q5, Q7, or Q8, you might notice:

• Rumbling noises from the front of the vehicle when driving over bumps or rough roads.
• Knocking noises from the front of the vehicle under similar conditions.

These symptoms are typically reproducible, meaning a technician should be able to hear the noise during a test drive.

Technical Background and Diagnosis

Audi's TSB 40 25 94 2059996/5 indicates that the underlying cause of this Audi front suspension noise can be tension within the vehicle body. This tension can affect the bolted connection of the strut brace, leading to the audible rumbling or knocking. The strut brace, also referred to as a tower brace, is a structural component designed to improve chassis rigidity.

For proper diagnosis, a workshop will attempt to reproduce the customer's reported noise. This helps confirm the complaint and ensures that the issue aligns with the conditions described in this TSB.

Repair Procedure Summary

The recommended repair outlined in TSB 40 25 94 2059996/5 focuses on the bolted connection of the two front strut braces. The procedure involves:

1. Noise Analysis: Technicians will first analyze the noise to confirm its origin.
2. Checking Bolted Connections: The bolted connections for both front strut braces must be inspected. Figure 1 in the TSB provides an example of a tower brace on an Audi Q7, illustrating the component in question.
3. Tightening to Correct Torque: If necessary, the bolts connecting the strut braces should be tightened to the precise torque specifications detailed in the official Workshop Manual.
4. Reassessment: After tightening, the vehicle should be re-evaluated to ensure the rumbling or knocking noise has been eliminated.

This TSB supersedes an earlier bulletin, Group 40 number 24-85, dated November 15, 2024, indicating updated information or procedures for this issue.

Important Warnings for Owners

Owners should be aware of several critical points regarding this TSB:

• Specific Conditions for Repair: The TSB explicitly states: "The following repair must only be carried out if all the criteria (model/type, chassis number, engine/motor and gearbox code, PR number(s), part number, software version, code etc.) apply exactly. Otherwise, this solution will not eliminate the problem, and repeat repairs may be necessary. In such a case, we may reject the warranty claim and charge back the cost of the parts." This means that if your vehicle does not precisely match the specified criteria, this particular repair might not be applicable or covered.
• Warranty Coverage: This TSB is informational only and is not applicable to any Audi Warranty. This is a crucial distinction, as it implies that the cost of diagnosis and repair related to this issue may not be covered under standard Audi warranty terms.
• Documentation for Billing: For any billing related to this repair, workshops are required to attach clear photos or videos demonstrating the complaint to DOC-IT. This documentation must include the VIN and date, be unedited, in focus, and clearly mark the problem location without showing personal data like faces or license plates.

What Owners Should Do

If your 2021-2025 Audi Q5, Q7, or Q8 is exhibiting rumbling or knocking noises from the front suspension, it is recommended to schedule an appointment with an authorized Audi service center. Be prepared to describe the conditions under which the Audi front suspension noise occurs. Discuss the implications of TSB 40 25 94 2059996/5 with your service advisor, especially concerning potential costs, given that the bulletin states it is not applicable to any Audi Warranty.

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Source: NHTSA ID: 11013720