2021 Audi Q8/SQ8/RS Q8 Cracking Roof Noise

Owners of 2021 Audi Q8, SQ8, and RS Q8 vehicles may notice an unusual cracking or snap-type noise emanating from the right rear roof area, particularly during abrupt steering thrusts or when the vehicle's body flexes. This condition is addressed by Audi Technical Service Bulletin (TSB) 2060145/4.

This bulletin, identified as TSB 51 21 22 2060145/4, supersedes previous bulletin Group 51 number 20-19 dated December 18, 2020. Revisions to the TSB included updates to warranty labor operations, changes in work procedures, and adjustments to required parts and tools, specifically the deletion of foam and addition of cavity wax.

Symptoms

Owners typically report a distinct noise in the right rear roof area of the cabin. This noise is often heard during an abrupt steering maneuver or when the vehicle body flexes. The sound is specifically described as a 'cracking' or 'snap' type of noise.

Diagnosis and Trigger Conditions

Workshop findings indicate that the noise originates from the right rear-most area of the sunroof opening, within the roof structure itself. The underlying cause is attributed to structural tolerances between the roof panel and the roof support sheet metal, which can generate these noises intermittently when the body flexes.

Technicians are advised to first confirm the symptom by test driving with the customer. It is crucial to ensure the noise type and location are clearly attributable to the issue described in TSB 2060145/4. If the noise cannot be duplicated during the test drive, the repair outlined in this TSB should not be performed.

Important Warnings

• Do not perform the repair in this TSB if the symptom cannot be duplicated during a test drive with the customer.
• Do not perform the repair in this TSB if the noise type and location are not clearly attributable to the issue described in the Technical Background section of the TSB.
• Use extreme caution during the repair process to avoid damaging the outer roof sheet metal.

Repair Procedure Summary

The repair procedure outlined in TSB 2060145/4 involves several steps to address the Audi Q8 cracking noises:

1. Preparation: The headliner and sliding sunroof assembly must be removed to access the affected area in the rear of the sunroof opening, starting with the right rear.
2. Separation: The outer roof sheet metal needs to be carefully separated from the inner roof support. This creates a small gap, approximately 1mm wide, between the two components.
3. Adhesive Release: If the sheet metal separation is difficult, a plastic mallet can be used for light strikes. For more stubborn areas, a small screwdriver or chisel may be used to carefully break away the adhesive.
4. Cavity Filling: The newly created gap is then filled with 3M 08852 Cavity Wax Plus. This wax helps to dampen vibrations and prevent the metal components from rubbing, thus eliminating the cracking noise.
5. Reassembly and Testing: After filling, the vehicle is reassembled. The procedure must be performed on both rear corners of the sunroof opening. A thorough test drive is required to ensure the noises have been eliminated.
6. Sunroof Adaptation: Following reassembly, the sunroof panel and rollershade end stop adaptation must be reset using the appropriate switches. For instructions on this, technicians should refer to TSB 2054505, which covers issues with sunroof glass panel or sunroof rollershade operation.

Required Tools or Parts

To perform the repair for the Audi Q8 cracking noises, the following specific part is required:

• 3M 08852 Cavity Wax Plus: This product is available through the Audi Top Service Supplies & Touch Up Paint eStore.

Additionally, fasteners, bolts, nuts, and screws may be needed for reassembly, as detailed in the repair manual.

Warranty Information

This Technical Service Bulletin covers repairs for up to 48 months or 50,000 miles, whichever comes first. If the vehicle is outside of this warranty period, the TSB serves as informational guidance only. Warranty claims must adhere to the Audi Warranty Policies and Procedures Manual.

Labor operations for this repair include:

• Headliner remove and reinstall (7084 1900)
• Sunroof frame remove and reinstall (6028 1950)
• Perform roof rework (5103 9999) – 30 Time Units (TU)
• Cavity wax applied (5101 7552)

Diagnostic time (GFF) is not allowed. Road tests before and after the service procedure are allocated 10 TU each.

Revision History

TSB 2060145/4 has undergone several revisions:

• Revision 4: Updated labor operations for warranty.
• Revision 3 (December 19, 2020): Changed work procedure, revised required parts and tools (deletion of foam, addition of cavity wax), and adjusted labor operations.
• Revision 2 (October 17, 2020): Revised header to add Model Year 2021.

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Source: NHTSA ID: 10193575