2021-2023 Audi e-tron Front End Noises TSB

Symptoms

Owners of 2021-2023 Audi e-tron vehicles may notice distinct Audi e-tron front end noises under specific driving conditions. These include:

• Rumbling, squeaking, or creaking sounds originating from the front end of the vehicle.
• Noises are particularly noticeable when driving on uneven road surfaces.
• The sounds often manifest at speeds below 20 mph.

Diagnosis / Trigger Conditions

Technicians can typically reproduce these Audi e-tron front end noises by driving the vehicle on uneven surfaces. The root cause of these sounds can be attributed to two main areas:

• Guide Link Hydro Bushing: The rattling or clacking noises from this component are often caused by an air bubble trapped inside the bushing during its manufacturing process. When vibrations are induced in the axle by uneven road surfaces, rapid changes in the bushing's internal pressure can cause the air bubble's volume to fluctuate, leading to noise, especially under certain temperature conditions.
• Drivetrain Components: Play within the electric motor, gearbox, or driveshafts can also generate knocking or rumbling noises. Due to the quiet nature of electric vehicles, these sounds are often more prominent in the cabin compared to combustion engine vehicles.

Repair Procedure Summary

Addressing the Audi e-tron front end noises involves a specific repair process outlined in Technical Service Bulletin 2066882/1. The general steps are as follows:

1. Initial Road Test: A road test is performed before any service to confirm the presence and characteristics of the front end noises.
2. Bushing Replacement: The primary repair involves replacing the guide link bushing on both sides of the vehicle's front suspension. This procedure requires detailed guidance from the ELSA Repair Manual, specifically the sections covering the chassis, suspension, wheels, steering, front suspension, lower control arm, and ball joint.
3. Wheel Alignment: After replacing the bushings, a wheel alignment must be performed to ensure proper vehicle handling and tire wear.
4. Final Road Test: A second road test is conducted after the repair to verify that the noises have been eliminated and the vehicle is operating correctly.

Required Tools or Parts

To perform this repair, specific parts are required, and technicians must adhere to the parts listed in this TSB, even if they supersede other part numbers. The necessary parts include:

• Part Number 4KC407183: Hydro mounting (Hydro bushing) - Quantity: 02
• Fasteners, bolts, nuts, and screws as needed, as specified in the ETKA/ELSA Repair Manual.

Important Warnings

Audi emphasizes the importance of using the correct parts for this repair. Technicians are advised:

• "Only use parts listed in this TSB, this includes superseding part numbers!"

Warranty Information

This repair for Audi e-tron front end noises is typically covered under warranty, subject to certain conditions:

• Standard Warranty: The repair is covered for up to 48 months or 50,000 miles.
• Certified Pre-Owned (CPO) Vehicles: For CPO vehicles, coverage falls under claim type G10, pending owner verification.
• Out-of-Warranty Vehicles: If the vehicle is outside its warranty period, this Technical Service Bulletin serves as informational guidance only.

Warranty Claim Details:

• Service Number: 4012
• Damage Code: 0020
• Labor Operations:
  • Replace 2 bushings for lower guide link: 4012 5650
  • Perform wheel alignment: 4495 0350
• Diagnostic Time: GFF (No allowance)
• Road Test Time:
  • Road test prior to service procedure: 0121 0002 (10 TU)
  • Road test after service procedure: 0121 0004 (10 TU)

NHTSA ID: 10210563