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

Owners of 2022-2024 Audi e-tron GT and RS e-tron GT vehicles may experience a specific gearbox issue identified by Technical Service Bulletin (TSB) 2073490/1. This bulletin, issued on May 28, 2024, addresses a condition where the dog clutch becomes stuck radially, leading to various performance limitations and warning messages. The Audi e-tron GT stuck dog clutch problem can significantly impact driving experience and vehicle functionality.

Symptoms

If your 2022-2024 Audi e-tron GT or RS e-tron GT is affected by a Audi e-tron GT stuck dog clutch, you may notice several symptoms:

• A "Gearbox fault message" displayed in the vehicle, indicating that the vehicle does not switch to second gear and its maximum speed is restricted to 74 mph.
• Unusual noises originating from the electric drive on the rear axle.
• A message stating, "Gearbox malfunction: you can continue driving. Please contact workshop" or a similar notification.

Fault Codes (DTCs)

When diagnosing a Audi e-tron GT stuck dog clutch, specific Diagnostic Trouble Codes (DTCs) may be stored in the Engine control module name -J623- (address word 0001). These codes help technicians pinpoint the exact nature of the fault.

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 are logged as both passive/intermittent and active/static. DTC entries P1C9800 and P101E00 may also be logged.

Technical Background

The underlying cause for these symptoms and fault codes is identified as the dog clutch being stuck radially. This mechanical issue prevents the gearbox from operating correctly, leading to the observed performance limitations and warning messages.

Important Warnings and Owner Advisories

Audi has issued several warnings and advisories related to diagnosing and resolving this issue:

• Road Test Safety: When performing a road test with an ODIS tester, accelerate the vehicle to a maximum of 31 mph and perform a load change. A second person must operate the ODIS tester to check for successful second gear shifts. This procedure can be aborted or repeated as needed.
• Distraction During Road Tests: Be aware that using application programs during driving can be distracting. Always observe road traffic regulations, which take priority over any driving instructions. A second person should operate test equipment, and the equipment itself should not distract the driver.
• Securing Test Equipment: Unsecured test equipment or equipment placed near airbags can cause injuries during maneuvers or accidents. Ensure all test equipment is properly secured and not transported in areas where airbags inflate. If possible, use the rear seat bench for test equipment; if not, keep it flat on the passenger's lap, operated by the passenger, with the seat moved as far back as possible.
• Parking on a Slope: Owners should be advised that when parking on a slope the electromechanical parking brake should be activated before releasing the foot brake and leaving the vehicle.
• No Electric Drive Motor Replacement: If the issue is resolved by advising the customer on proper parking brake use on slopes, it is not necessary to replace the electric drive motor for the rear axle.

Repair Procedure Summary

The repair for the Audi e-tron GT stuck dog clutch involves two main sections: a software update and a diagnostic check based on DTC entries, as detailed in TSB 2073490/1.

Section 1: Software Update

The initial step is to perform a software update via SVM code, as detailed in TSB 2073768, titled "Combined software update Audi e-tron GT". If the vehicle's current software is not covered by this TSB, technicians should proceed directly to Section 2.

Section 2: Checking Vehicle Health Based on DTC Entries

There are two procedures to identify a stuck dog clutch:

Procedure 1: DTC-Based Identification

1. Identify the stuck dog clutch based on the combination of DTCs P1D2E00, P1D4500, and P1D2D00.
2. Check the frequency counter under "Standard ambient conditions" for these DTC entries.
3. If any of these DTC entries has a frequency count of 5 or more:
   • Ask the customer if the vehicle was parked on a slope before the fault occurred.
   • If the vehicle is regularly parked on a slope, explain the recommendation regarding the electromechanical parking brake to the customer.
4. Perform Guided Fault Finding for the identified DTC entries.

Procedure 2: Comprehensive DTC and Physical Inspection

1. Identify the stuck dog clutch based on DTCs P1D2E00, P1D4500, and P1D2D00, along with additional DTCs P1C9800 and P101E00, all stored in diagnostic address 0001.
2. If these DTC entries are logged when the complaint occurs, check for any unusual noises or the presence of large shavings (not abrasion particles) and/or broken pieces that have broken off in the gear oil.
3. If noises or large shavings/pieces are found in the gear oil, replace the 2-speed rear axle transmission unit according to the instructions in the Workshop Manual.

Warranty Information

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

• Claim Type: 110 (Up to 48 Months/50,000 Miles) or G10 (for CPO Covered Vehicles – verify owner). If the vehicle is outside of any warranty, this TSB is for informational purposes only.
• Service Number: 9340
• Damage Code: 0010
• Labor Operations:
  • Drain and fill up gear oil: 3401 1753 (See SRT with associated operations)
  • Check gear oil: 3401 0199 (10 Time Units)
  • 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 Time Units)
  • Test drive before service procedure: 0121 0002 (10 Time Units)
  • Test drive after service procedure: 0121 0004 (10 Time Units)
• Claim Comment: As per TSB 2073490/1.

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 and parts bulletins.

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

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Source: NHTSA ID: 10255307