2021-2023 Audi Front End Cracking Noise TSB

Owners of certain 2021-2023 Audi A3, S3, RS 3, and Q3 models may notice an "Audi front end cracking noise" when changing direction. This issue is addressed by Audi Technical Service Bulletin (TSB) 2061464/3, which supersedes an earlier bulletin, Group 40 number 21-23, dated February 16, 2021.

This TSB, identified as 40 22 43 2061464/3, provides a detailed procedure for technicians to resolve the cracking noise, ensuring a proper and lasting repair. The bulletin was most recently revised on June 9, 2022, to include additional models and model years.

Symptoms

Owners typically report a distinct "cracking noise from front end when changing direction." This sound is often described as a "one-off cracking noise from the front after changing directions" specifically when pulling away from a stop or changing direction.

Technical Background

Audi's investigation into the "Audi front end cracking noise" determined that the root cause is relative movement of the drive axle within the wheel bearings. This slight movement creates the audible cracking sound reported by drivers.

Production Solution

Audi has implemented a production solution by gradually introducing improved drive axles in newer vehicles. However, for affected vehicles already on the road, a specific service procedure is required to address the issue.

Repair Procedure Summary

To correct the "Audi front end cracking noise," technicians will follow a specific repair procedure. This involves disassembling the affected drive axle according to instructions found in the Elsa repair manual under Chassis >> Suspension, Wheels, Steering >> 40 Front Suspension >> Front Axle >> Drive Axle Disassembling, Assembling.

Once disassembled, a liquid locking fluid, identified by part number D 154100A1, is applied to the threaded connection of the drive axle. After the application of the locking fluid, the drive axle is reinstalled following the same Elsa instructions.

Required Parts and Tools

The primary part required for this repair is the locking fluid, part number D 154100A1, with a quantity of 0.2. Additionally, fasteners, bolts, nuts, and screws may be needed as per the repair manual, which can be referenced through ETKA.

Important Warnings

It is crucial to note a specific warning associated with this repair: After assembling the drive axle(s), the vehicle must not be operated for 8 hours. This waiting period is necessary to allow the liquid locking fluid to properly cure and ensure the effectiveness of the repair.

Warranty Information

This repair is covered under Audi's warranty for up to 48 months or 50,000 miles, under Claim Type 110. The service number for this bulletin is 4045, and the damage code is 0010. Labor operations include "Driveshaft Remove + Reinstall (1)" (code 4041 1900) and "Driveshaft Remove + Reinstall (2)" (code 4041 2000). Diagnostic time is recorded under GFF (0150 0000), with additional time for road tests prior to (0121 0002) and after (0121 0004) the service procedure. All warranty claims must adhere to the Audi Warranty Policies and Procedures Manual.

Owner Action

If your 2021-2023 Audi A3, S3, RS 3, or Q3 is exhibiting a "cracking noise from front end when changing direction," you should contact your authorized Audi dealership. Inform them about the symptoms you are experiencing and mention Technical Service Bulletin 2061464/3. The dealership will diagnose the issue and perform the necessary repair, which is covered under warranty for eligible vehicles.

Source: NHTSA ID 10214460