2020-2025 Audi Rear Suspension Noises TSB 2038689/9

Owners of various 2020-2025 Audi models may experience bothersome rumbling or squeaking noises emanating from the rear of their vehicle. This issue is specifically addressed by Audi Technical Service Bulletin (TSB) 2038689/9, which provides guidance for technicians on diagnosing and resolving the problem of "Audi rear suspension noises."

Symptoms

Customers frequently report hearing distinct "rumbling or squeaking noises from the rear end of the vehicle." These sounds are typically attributed to the shock absorber bump stops. The bump stops, which are crucial components of the suspension system, may be incorrectly seated within their shock absorber mounting or could have completely fallen out.

Technical Background

The redevelopment of Audi's suspension systems has led to an increase in the hardness of the bump stops. This design change makes it more challenging to correctly press the bump stops into their mountings during assembly. If the additional spring is not properly pushed back into the shock absorber mounting during the pre-delivery inspection (PDI), the bump stop may drop onto the shock absorber tube, leading to the reported noises.

Diagnosis

Technicians should investigate the rear of the vehicle for the source of the rumbling or squeaking noises. The TSB specifies that the bump stops of the shock absorbers are identified as the primary cause when they are not seated correctly in the shock absorber mounting or have fallen out.

Repair Procedure Summary

The recommended service procedure focuses on correctly securing the bump stops. Technicians should perform the following steps:

1. Secure Bump Stops: Ensure the bump stops are pressed all the way into their correct position.
2. Special Tool Use: An "Assembly lever T40401 (SET 900)" can be utilized to aid in securing the bump stops.
3. Lubrication: A tire assembly paste can be used as an aid to facilitate proper seating.
4. Reshaping (if necessary): If the bump stops are found to be deformed, they can be reshaped correctly by warming them up slightly.

Important Notices

Audi has issued a critical notice regarding this issue:

"Please ensure that the bump stops are completely secured manually during the pre-delivery inspection."

This highlights the importance of proper installation during the initial vehicle preparation to prevent the occurrence of "Audi rear suspension noises."

TSB Revision History

This Technical Service Bulletin has undergone several revisions to refine the service procedure and update information:

• Revision 9 (Date not specified): Revised Service (Updated procedure) and Revised Condition (Updated Information).
• Revision 8 (December 12, 2023): Revised Service (Updated procedure).
• Revision 7 (August 4, 2023): Revised header, including the addition of new Model Years.

Warranty Information

Audi states that this TSB is for informational purposes only and is not applicable to any Audi Warranty. Owners should consult their dealership regarding potential costs for addressing "Audi rear suspension noises."

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Source: NHTSA ID: 2038689/9