2021-2022 Audi Rear Suspension Rattle TSB

Symptoms

Owners of 2021-2022 Audi vehicles, including the e-tron, may experience specific auditory issues from the rear suspension. The primary symptom reported is "Clunking or rattling noises are heard from the rear suspension area when the vehicle is driven over bumps."

If you notice an e-tron rear suspension rattle or similar sounds while driving over uneven surfaces, this technical service bulletin provides insight into the potential cause and remedy.

Technical Background

The root cause of the e-tron rear suspension rattle is often an improperly seated rear bump stop. This condition occurs when the rear bump stop was not fully inserted into the rear shock absorber mounting during the vehicle's Pre-Delivery Inspection (PDI).

To address this, Audi developed a specific production solution: the SET900 bump stop installation tool. This tool provides the necessary leverage to ensure the rear bump stop is properly seated in the shock absorber mounting, preventing future issues.

Repair Procedure Summary

To effectively resolve the rear suspension rattle, technicians will follow a precise procedure to ensure the rear bump stops are correctly installed. This process involves several key steps:

1. Preparation: The top surfaces of the rear bump stops must be thoroughly cleaned. Following cleaning, a layer of tire mounting paste is applied to these surfaces.
2. Installation: The specialized SET900 bump stop installation tool is then used to fully press the rear bump stops into their designated upper shock mounts. This tool is crucial for properly seating the bump stops, preventing them from dislodging and causing the noise.
3. Verification: After installation, technicians must ensure that the dust boot is not caught on the top of the shock absorber as the vehicle is lowered, which could impede proper function or cause damage.

This procedure aims to permanently correct the improper seating of the rear bump stops, thereby eliminating the e-tron rear suspension rattle.

Required Tools

The repair for the rear suspension rattle requires a specific tool to ensure proper installation:

• SET900: This is a dedicated bump stop installation tool. Audi initially distributed one SET900 tool to all authorized dealers in November 2014. Additional tools can be purchased through the Audi Special Tools and Equipment Program if needed.

Important Warnings

Owners should be aware of the following important information regarding this Technical Service Bulletin:

• Warranty Coverage: This TSB (bulletin number 42 21 46 2038689/5) is explicitly stated as being