2022-2026 Audi Models Brake Disc Corrosion TSB

Owners of 2022-2026 Audi models may notice a rust layer on their brake discs or experience noises and vibrations during braking. These issues are detailed in Audi Technical Service Bulletin (TSB) 2067132/3, which provides information regarding corrosion on the friction surface of steel brake discs. This TSB clarifies that such conditions are often a result of environmental exposure and specific driving habits, rather than a manufacturing defect. For example, if you own an Audi e-tron brake disc corrosion might be a concern you've encountered.

Symptoms

Owners typically report the following observations related to this condition:

• Rust layer on the brake disc: A visible layer of rust on the friction surface of the steel brake discs.
• Noises when braking: Squealing, grinding, or other unusual sounds during brake application.
• Vibrations when braking: A pulsating or shaking sensation felt through the brake pedal or steering wheel during braking.

These symptoms are often confirmed by workshop technicians as part of the diagnostic process.

Technical Background and Trigger Conditions

Corrosion on the friction surface of steel brake discs can occur due to several factors, primarily related to environmental exposure and brake usage patterns. The TSB explains that moisture and road salt are significant contributors, especially if the vehicle is stationary for extended periods. Additionally, if the brakes are only used lightly during short journeys, it can lead to insufficient brake cleaning, allowing corrosion to develop.

Audi notes that brake discs are constantly exposed to environmental elements such as water, salt, snow, and dirt. The material used for these brake discs, flake graphite cast iron, is not inherently resistant to corrosion. It is also technically not possible to apply an anti-corrosion coating directly to the friction surfaces of the brake disc. The TSB includes examples of excessively rusted disc brakes (Figure 1) and rusted brake disc surfaces (Figure 2) to illustrate the issue.

Repair Procedure Summary

Addressing brake disc corrosion involves a specific service procedure, although it's important to note that this TSB is informational and the issue is generally not covered under Audi's warranty if caused by insufficient brake cleaning.

The recommended steps include:

1. Extensive Test Drive: Perform a thorough test drive involving several brake operations to attempt to "clean" the brake discs.
2. Pads Contact Check: Verify that the brake pads are making correct contact with the disc, ensuring they are cleaning the entire surface effectively.
3. Intensive Braking: If the complaint persists, technicians are advised to intensively "brake clean" the discs.
4. Part Replacement: If intensive braking does not resolve the issue, replacing the affected brake discs and pads is the only remaining option.
5. Customer Education: Explain to the customer the importance of proper brake maintenance and cleaning as outlined in the Owner's Manual.

No specific part numbers or special tools are mentioned in this bulletin for this procedure.

Owner Action

If you observe a rust layer on your brake discs or experience noises and vibrations during braking, especially if you drive an Audi e-tron brake disc corrosion could be the cause. It is recommended to:

• Regularly use your brakes: Ensure your brakes are used sufficiently to keep the friction surfaces clean. Light braking or infrequent use, particularly in humid or salty conditions, can exacerbate corrosion.
• Consult your Owner's Manual: Follow the maintenance guidelines provided by Audi regarding brake care.
• Contact your Audi dealer: If symptoms persist after regular driving, have a qualified technician inspect your vehicle. Be aware that issues stemming from insufficient brake cleaning are typically not covered under Audi's warranty.