2021-2023 Audi Door Handle Binding TSB

Audi has issued Technical Service Bulletin (TSB) 2060196/4, superseding TSB Group 57 number 21-80, to address issues with exterior door handles on several 2021-2023 Audi models. This bulletin provides detailed instructions for diagnosing and repairing door handles that bind, protrude, or fail to return to their zero position.

Symptoms

Owners of affected Audi vehicles may observe several issues related to the door handles. The most common complaints include:

• "Central locking and/or door open warnings displayed in the instrument cluster."
• "The doors are not closing and/or locking properly."
• "The door handles are binding and protruding."

Workshop findings confirm that exterior door handles are binding and are not returning to the zero position as they should. If you experience these symptoms, your vehicle may be affected by the Audi e-tron door handle binding issue.

Technical Background

According to Audi, the root cause of this problem is material tolerances. These tolerances lead to the door handle guide binding within the door handle mounting bracket. This binding prevents the handles from functioning correctly and returning to their intended position.

Audi has implemented improved parts in production to mitigate this issue in newer vehicles. However, existing vehicles may still require the specified repair.

Repair Procedure Summary

Addressing the Audi e-tron door handle binding involves a multi-step process performed by a qualified technician:

1. Initial Check: All door handles are inspected to ensure they return to the zero position without binding or jamming.
2. Handle Removal: Affected door handles are carefully removed following the repair manuals in Elsa.
3. Rib Modification: Using precision diagonal cutting pliers, door handle ribs #1 and #2 on the pivot side of the mounting bracket (towards the front of the vehicle) are removed. The resulting surface must be smooth and free of protrusions.
4. Rib #3 Adjustment: A vernier caliper is used to measure the dimension from the bottom edge of the door handle to the top of rib #3. This rib is then scraped with a precision/utility knife until the dimension is approximately 20.9 mm (0.82 inches).
5. Sanding: The top surface of rib #3 is sanded down until the measurement is approximately 20.6 mm (0.81 inches).
6. Guide Piece Replacement: The door handle guide piece on the lock cylinder side (towards the back of the vehicle) is replaced with a new part (part number 4N0837259).
7. Reinstallation and Verification: All door handles are reinstalled according to Elsa repair manuals, and their normal function is verified.

Required Tools or Parts

Technicians will need specific tools and parts to perform this repair:

• Part Number 4N0837259: Guide Piece (01-04 units as needed)
• Fasteners, Bolts, Nuts, and Screws: As specified in ETKA/ELSA repair manuals.
• Precision diagonal cutting pliers
• Vernier caliper
• Precision/utility knife
• Sanding paper

What Owners Should Know

• Warranty Coverage: The repair is covered under Audi's warranty for vehicles within 48 months or 50,000 miles. For Certified Pre-Owned (CPO) vehicles, coverage is subject to owner verification.
• Out-of-Warranty Vehicles: If your vehicle is outside of the warranty period, this Technical Service Bulletin serves as informational guidance only, and repair costs may apply.
• Production Improvements: Audi has implemented improved parts in production, meaning newer vehicles may not experience this specific issue.

Owner Action

If your 2021-2023 Audi e-tron, or any other affected model, is exhibiting symptoms such as binding or protruding door handles, or if you see "Central locking and/or door open warnings displayed in the instrument cluster," it is recommended to schedule an appointment with an authorized Audi service center. Provide them with the TSB number 2060196/4 for reference.

NHTSA ID: 10232097