2022-2024 Audi e-tron GT / RS e-tron GT Stuck Dog Clutch TSB

Symptoms of a Stuck Dog Clutch

Owners of 2022-2024 Audi e-tron GT and RS e-tron GT vehicles may experience specific symptoms indicating an Audi e-tron GT stuck dog clutch issue. These include a "Gearbox fault message shown in vehicle" on the instrument cluster, which also states that the vehicle "does not switch to second gear and max. speed is restricted to 74 mph." Some owners may also notice noises emanating from the electric drive on the rear axle. A common message displayed to the driver is "Gearbox malfunction: you can continue driving. Please contact workshop" or a similar warning.

Affected Fault Codes (DTCs)

When diagnosing an Audi e-tron GT stuck dog clutch, technicians may find several Diagnostic Trouble Codes (DTCs) stored in the Engine control module name -J623- (address word 0001). The following DTCs are particularly relevant:

Code	Description	Symptom Code	Status
P1D2E00	Claw coupling Time exceeded for display	43976	passive/intermittent or active/static
P1D4500	Disk clutch 2nd gear Time exceeded for opening	44008	passive/intermittent or active/static
P1D2D00	Claw coupling Display attempt failed	43979	passive/intermittent or active/static
P1C9800	Electrical transmission actuator blocked	40335	passive/intermittent or active/static
P101E00	RPM limit due to excess temperature	42659	passive/intermittent or active/static

DTC entries P1D2E00, P1D4500, and P1D2D00 must occur in combination and be logged as both passive/intermittent and active/static to confirm a stuck dog clutch. DTCs P1C9800 and P101E00 may also be present, indicating related issues.

Technical Background

This issue stems from the dog clutch becoming stuck radially within the transmission. The dog clutch is a critical component responsible for engaging and disengaging gears. When it becomes stuck, it prevents the vehicle from shifting properly, leading to the observed speed restrictions and gearbox malfunction messages.

Diagnosis and Trigger Conditions

Diagnosing the Audi e-tron GT stuck dog clutch involves two main procedures. The first step for technicians is to confirm if the dog clutch is still actively engaged and if the vehicle is unable to shift into second gear. If these conditions are met, a specific diagnostic road test is performed.

This road test requires accelerating the vehicle from a standstill to a maximum speed of 31 mph and performing a load change by pressing the accelerator. A second person must use an ODIS tester to monitor whether the vehicle shifts into second gear. If the vehicle successfully shifts into second gear during this test, the dog clutch has been released, and the procedure can be stopped or repeated.

Important Warnings for Road Tests:

• Using application programs during driving can be distracting. Always prioritize road traffic regulations over driving instructions.
• A second person must always operate the test equipment during a road test.
• Ensure test equipment in the vehicle does not distract the driver.
• Unsecured test equipment can cause injuries in certain maneuvers or accidents. Secure all test equipment properly and do not transport it in areas where airbags inflate.
• If possible, place test equipment on the rear seat bench. If no rear seat bench is available, keep it flat on the passenger's lap, with the passenger operating it and their seat moved as far back as possible.

There are two different procedures for identifying a stuck dog clutch based on DTC entries:

Procedure 1: DTC Analysis

This procedure focuses on DTCs P1D2E00, P1D4500, and P1D2D00. Technicians check the frequency counter under "Standard ambient conditions" for these entries. If any of these DTCs have a frequency count of 5 or more, the customer should be asked if the vehicle was parked on a slope before the fault occurred. If the vehicle is regularly parked on a slope, the customer should be advised on proper parking techniques (see owner action below). Guided Fault Finding is then performed for these DTC entries.

Procedure 2: Comprehensive DTC Analysis and Physical Inspection

This procedure considers DTCs P1D2E00, P1D4500, P1D2D00, P1C9800, and P101E00. If these DTCs are logged when the complaint occurs, technicians must check for any unusual noises and for large shavings (not abrasion particles) or pieces that have broken off in the gear oil.

Repair Procedure Summary

Repair for the Audi e-tron GT stuck dog clutch involves two main sections as outlined in Technical Service Bulletin 2073490/1:

Section 1: Software Update

Perform a software update via SVM code, as detailed in TSB 2073768, titled "Combined software update Audi e-tron GT". Vehicles with software not included in this TSB should proceed directly to Section 2 for further diagnosis.

Section 2: Checking Vehicle Health Based on DTC Entries

This section follows the diagnostic procedures described above. If Procedure 2 reveals noises and/or large shavings or broken pieces in the gear oil, the 2-speed rear axle transmission unit must be replaced according to the instructions in the Workshop Manual.

Important Warnings for Owners

Audi advises customers that when parking on a slope, the electromechanical parking brake should always be activated before releasing the foot brake and leaving the vehicle. This practice can help prevent conditions that may contribute to a stuck dog clutch.

It is important to note that if the issue is a stuck dog clutch as described in TSB 2073490/1, it is explicitly stated that it is not necessary to replace the electric drive motor for the rear axle.

Warranty Information

This Technical Service Bulletin 2073490/1 outlines the following warranty claim details:

• Claim Type: 110 (Up to 48 Months/50,000 Miles) or G10 for CPO (Certified Pre-Owned) Covered Vehicles, requiring owner verification.
• If the vehicle is outside of any warranty, this TSB is for informational purposes only.
• Service Number: 9340
• Damage Code: 0010

All warranty claims must adhere to the Audi Warranty Policies and Procedures Manual and are subject to review or audit.

Required Parts and Tools

Technicians should consult their Parts Department and/or ETKA for the latest information on parts. For repairs involving transmission unit replacement, the following parts are generally required:

Part Number	Part Description	Quantity
See ETKA	Fasteners, Bolts, Nuts, and Screws as needed per the Repair Manual	See ETKA/ELSA
See ETKA	Gear oil	See ETKA/ELSA
See ETKA	Gearbox	01

An ODIS tester is a required tool for diagnostic procedures and monitoring during road tests.

Labor Operations

Specific labor operations and time units (TU) are allocated for addressing the Audi e-tron GT stuck dog clutch issue:

Labor Operation	Code	Time Units (TU)
Drain and fill up gear oil	3401 1753	See SRT with associated operations
Check gear oil	3401 0199	10
Remove and install gearbox	3435 1953	See SRT with associated operations
Replace gearbox	3435 5553	See SRT with associated operations
Diagnostic Time (GFF)	0150 0000	Labor according to diagnostic log (Max 100 TU)
Test drive before the service procedure	0121 0002	10
Test drive after the service procedure	0121 0004	10

Claim comments should reference TSB 2073490/1.

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Source: NHTSA ID: 10255395