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

Owners of 2022-2024 Audi e-tron GT and RS e-tron GT models may encounter issues related to a stuck dog clutch. This condition can lead to various symptoms, including warning messages and performance limitations. Audi has issued Technical Service Bulletin (TSB) 2073490/2 to provide diagnostic and repair procedures for this specific problem.

This TSB, identified as 93 24 15 2073490/2, supersedes an earlier bulletin, Group 93 number 24-57, dated May 28, 2024, indicating an updated measure to address the issue. The primary concern is a radially stuck dog clutch within the vehicle's transmission system.

Revision History

This Technical Service Bulletin has undergone the following revisions:

Revision	Date	Purpose
2	-	Revised Service (Updated measure)
1	05/28/2024	Initial publication

Symptoms

If your Audi e-tron GT dog clutch is affected, you might experience the following:

• A "Gearbox fault" message shown in the vehicle's instrument cluster. The vehicle may not switch to second gear, and its maximum speed can be restricted to 74 mph.
• Noises from the electric drive on the rear axle.
• The message "Gearbox malfunction: you can continue driving. Please contact workshop" or a similar warning is displayed.

Workshop findings have confirmed these customer-reported symptoms.

Diagnostic Trouble Codes (DTCs)

The following Diagnostic Trouble Codes (DTCs) and symptom code(s) may be stored in the Engine control module (J623, address word 0001) when the Audi e-tron GT dog clutch is stuck:

• P1D2E00: Claw coupling Time exceeded for display (Symptom: 43976 passive/intermittent or active/static).
• P1D4500: Disk clutch 2nd gear Time exceeded for opening (Symptom: 44008 passive/intermittent or active/static).
• P1D2D00: Claw coupling Display attempt failed (Symptom: 43979 passive/intermittent or active/static).

These three DTCs (P1D2E00, P1D4500, and P1D2D00) must occur in combination and be logged as both passive/intermittent and active/static for the primary diagnosis. Additionally, the following DTCs may also be logged:

• P1C9800: Electrical transmission actuator blocked (Symptom: 40335 passive/intermittent or active/static).
• P101E00: RPM limit due to excess temperature (Symptom: 42659 passive/intermittent or active/static).

Technical Background

The root cause of these symptoms and DTCs is that the dog clutch, a component within the transmission, is stuck radially.

Diagnosis and Repair Procedures

There are two main procedures for identifying a stuck dog clutch on the e-tron GT:

Procedure 1: Checking Event Memory Entries

Technicians will check the frequency counter under "Standard ambient conditions" for DTCs P1D2E00, P1D4500, and P1D2D00. If any of these DTCs have a frequency count of 5 or more, the technician will:

1. Ask the customer if the vehicle was parked on a slope before the fault occurred.
2. If the vehicle is regularly parked on a slope, explain the recommendation for proper parking.
3. Perform Guided Fault Finding for the listed DTC entries.

Procedure 2: Identifying Stuck Dog Clutch with Additional DTCs

This procedure involves identifying the primary stuck dog clutch DTCs (P1D2E00, P1D4500, P1D2D00) along with P1C9800 and P101E00. If these DTCs are logged, the technician will check for any noises or large shavings (not abrasion particles) or broken pieces in the gear oil.

Important Warnings for Owners and Technicians

• Parking on a Slope: When parking on a slope, the electromechanical parking brake should be activated before releasing the foot brake and leaving the vehicle. This practice can help prevent conditions that might lead to the Audi e-tron GT dog clutch becoming stuck.
• Electric Drive Motor: It is explicitly stated that in this case, it is not necessary to replace the electric drive motor for the rear axle.
• Transmission Replacement: If noises occur and/or there are large shavings (not abrasion particles) and/or pieces that have broken off in the gear oil, the 2-speed rear axle transmission unit must be replaced according to the instructions in the Workshop Manual.
• Road Test Safety: When performing a road test with an ODIS tester, be aware that using application programs while driving can be distracting. Always observe road traffic regulations, prioritize them over driving instructions, and perform the road test with a second person operating the test equipment. Ensure test equipment does not distract the driver.
• Test Equipment Transport: Unsecured test equipment or equipment placed in the range of airbags can cause injuries in an accident. Secure all test equipment properly and do not transport it in areas where airbags inflate. If possible, use test equipment on the rear seat bench. If no rear seat bench is available, keep the equipment flat on the passenger's lap, with the passenger operating it and their seat moved as far back as possible.

Repair Procedure Summary

The work to address the Audi e-tron GT dog clutch issue comprises two sections:

Section 1: Software Update

This involves a software update for the vehicle under campaign 91VT.

Section 2: Dog Clutch Release Procedure

To check if the dog clutch is still actively engaged and if the vehicle does not shift into 2nd gear, a specific test is performed. The vehicle is accelerated from a standstill to a maximum speed of 31 mph, and a load change is performed by pressing the accelerator. Simultaneously, a second person uses an ODIS tester to check if the vehicle shifts into second gear. If it shifts, the dog clutch was successfully released.

Warranty Information

For vehicles outside of warranty, this Technical Service Bulletin is informational only. For in-warranty repairs, claims must adhere to the Audi Warranty Policies and Procedures Manual.

• Service Number: 9340
• Damage Code: 0010
• Claim Comment: As per TSB 2073490/2

Labor Operations:

Labor Operation	Time Units (TU)	Description
3401 1753	See SRT with associated operations	Drain and fill up gear oil
3401 0199	10 TU	Check gear oil
3435 1953	See SRT with associated operations	Remove and install gearbox
3435 5553	See SRT with associated operations	Replace gearbox
0150 0000	Labor according to the diagnostic log	GFF (Guided Fault Finding)
2706 8950	See SRT with associated operations	Charge Battery
0121 0002	10 TU	Test drive before the service procedure
0121 0004	10 TU	Test drive after the service procedure

Required Parts and Tools

Always consult your 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: 10257321