2021-2025 Audi Cracking Noise When Changing Direction TSB

Symptoms of Cracking Noise

Owners of affected 2021-2025 Audi vehicles may notice a distinct cracking noise. This noise typically occurs when changing direction, originating from either the front or rear end of the vehicle.

Another common scenario is hearing a cracking noise from the left or right side of the vehicle's front or rear end when driving away from a standstill, especially after changing direction. This symptom is particularly relevant for quattro models.

Technical Background

Audi has identified the root cause of the cracking noise as relative movement of the stub axle of the drive shaft within the wheel bearing. This movement creates the audible cracking sound reported by owners.

For quattro vehicles, the noise in isolated cases has also been attributed to the prop shaft. This technical insight helps technicians accurately diagnose the specific source of the Audi e-tron cracking noise or similar issues in other models.

Production Solution

To address this issue in new vehicle production, Audi has gradually introduced optimized stub axle splines in the outer joint. This design change aims to prevent the relative movement that causes the cracking noise, improving long-term durability.

Repair Procedure Summary

For vehicles experiencing the cracking noise, Technical Service Bulletin (TSB) 2061464/8 outlines a specific repair procedure. The repair involves bonding the stub axle of the drive shaft into the wheel bearing using a specialized locking fluid.

Technicians must follow detailed instructions provided in the ELSA Repair Manual, specifically under "Chassis >> Suspension, Wheels, Steering >> 40 Front Suspension >> Front Axle >> Drive Axle >> Drive Axle Disassembling, Assembling." Approximately 5 ml of locking fluid (part number D 154100A1) is required for each drive shaft, applied as two continuous adhesive beads. The first bead is applied where the splines begin, and the second is at the center of the splines. After applying the fluid, the drive axle is reinstalled according to ELSA instructions. This procedure resolves the Audi e-tron cracking noise by stabilizing the stub axle.

Required Parts and Tools

To perform the repair described in TSB 2061464/8, specific materials are required:

• Locking fluid: Part number D 154100A1. Approximately 0.2 units (e.g., bottles) are needed.
• Fasteners, Bolts, Nuts, and Screws: As needed, per the ELSA Repair Manual and ETKA.

Technicians should always consult their Parts Department and/or ETKA for the latest information on parts and bulletins.

Important Warnings

WARNING: After assembling the drive axle(s), the vehicle must not be operated for 8 hours. This crucial waiting period ensures the locking fluid properly cures and bonds the components, preventing a recurrence of the cracking noise and ensuring vehicle safety.

Warranty Information

Warranty claims for this repair, identified by service number 4041/4221 and damage code 0010, must be submitted in accordance with the Audi Warranty Policies and Procedures Manual. The claim comment should reference TSB 2061464/8. If the vehicle is outside of its warranty period, this Technical Service Bulletin is for informational purposes only, and repair costs may not be covered.

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Source: NHTSA ID: 11009939