2022-2024 Audi e-tron GT Stuck Dog Clutch TSB

Audi has issued Technical Service Bulletin (TSB) 2073490/3 to address instances of a stuck dog clutch in 2022-2024 Audi e-tron GT and RS e-tron GT vehicles. This condition can trigger specific diagnostic trouble codes (DTCs) and lead to noticeable symptoms for drivers.

The TSB, which supersedes bulletin 93 24-15 dated September 18, 2024, provides updated warranty and service measures for this issue. Owners experiencing symptoms related to a stuck dog clutch should be aware of this bulletin.

Symptoms of a Stuck Dog Clutch

Owners of affected Audi e-tron GT models may observe the following:

• A "Gearbox fault message shown in vehicle" which restricts the vehicle's maximum speed to 74 mph and prevents it from shifting into second gear.
• Unusual noises emanating from the electric drive on the rear axle.
• A dashboard message stating, "Gearbox malfunction: you can continue driving. Please contact workshop" or a similar warning.

These symptoms are often confirmed by technicians during workshop visits.

Fault Codes / DTCs

The Engine control module (-J623-, address word 0001) may store several diagnostic trouble codes (DTCs) related to a stuck dog clutch. These codes indicate specific issues with the clutch and gear operation:

• P1D2E00: Claw coupling Time exceeded for display (Symptom: 43976 passive/intermittent or active/static).
• P1D4500: Disk clutch 2nd gear Time exceeded for opening (Symptom: 44008 passive/intermittent or active/static).
• P1D2D00: Claw coupling Display attempt failed (Symptom: 43979 passive/intermittent or active/static).
• P1C9800: Electrical transmission actuator blocked (Symptom: 40335 passive/intermittent or active/static).
• P101E00: RPM limit due to excess temperature (Symptom: 42659 passive/intermittent or active/static).

It is important to note that DTC entries P1D2E00, P1D4500, and P1D2D00 must occur in combination and be logged as both passive/intermittent and active/static to indicate a stuck dog clutch.

Diagnosis and Trigger Conditions

Diagnosis involves checking for the presence and frequency of the listed DTCs. If any of the DTCs (P1D2E00, P1D4500, P1D2D00) have a frequency count of 5 or more under "Standard ambient conditions," further investigation is required. Technicians will also inquire if the vehicle was regularly parked on a slope before the fault occurred, as this can be a contributing factor to the Audi e-tron GT stuck dog clutch issue.

An initial check involves accelerating the vehicle from a standstill to a maximum speed of 31 mph and performing a load change by pressing the accelerator. A second person using an ODIS tester simultaneously checks if the vehicle shifts into second gear. If it does, the dog clutch has successfully released.

Important Warnings for Owners and Technicians

Audi provides several critical warnings within TSB 2073490/3:

• Road Test Safety: When performing road tests or adaptation drives with an ODIS Tester, technicians must prioritize road traffic regulations. Using application programs during driving can be distracting. Road tests should always be performed with a second person operating the test equipment to avoid distracting the driver.
• Unsecured Test Equipment: There is a danger associated with transporting unsecured test equipment. If equipment is unsecured or placed near airbags, it could cause injuries in an accident. Always secure test equipment properly and avoid transporting it in areas where airbags inflate. If possible, use the rear seat bench for test equipment; otherwise, keep it flat on the passenger's lap, with the passenger operating it and their seat moved as far back as possible.
• Parking on Slopes: Owners should be advised that when parking on a slope, the electromechanical parking brake must be activated before releasing the foot brake and leaving the vehicle. This practice can help prevent the Audi e-tron GT stuck dog clutch condition.
• Unnecessary Part Replacement: If the issue is related to parking on a slope, it is not necessary to replace the electric drive motor for the rear axle.

Repair Procedure Summary

The repair for a stuck dog clutch in the Audi e-tron GT involves two main sections:

Section 1: Software Update

The first step is to perform a software update for the vehicle, specifically campaign 91VT.

Section 2: Checking Vehicle Health and Further Actions

This section outlines two procedures based on the DTC entries:

Procedure 1: For DTCs P1D2E00, P1D4500, P1D2D00 (frequency count of 5 or more)

1. Confirm with the customer if the vehicle was parked on a slope before the fault occurred.
2. If the vehicle is regularly parked on a slope, advise the customer to activate the electromechanical parking brake before releasing the foot brake.
3. Perform Guided Fault Finding for the specific DTCs.

Procedure 2: For DTCs P1D2E00, P1D4500, P1D2D00, P1C9800, and P101E00 (all logged)

1. Check for any unusual noises, large shavings (not just abrasion particles), or pieces broken off in the gear oil.
2. If noises, large shavings, or broken pieces are found, the 2-speed rear axle transmission unit must be replaced according to the instructions in the Workshop Manual.

Warranty Information

This Technical Service Bulletin (TSB 2073490/3) is informational only if the vehicle is outside of its warranty period. For in-warranty repairs, claims must adhere to the Audi Warranty Policies and Procedures Manual. The service number for this issue is 9340, with a damage code of 0010.

Labor operations include:

• Drain and fill up gear oil (Operation 3401 1753, 10 TU)
• Check gear oil (Operation 3401 0199, 10 TU)
• Remove and install gearbox (Operation 3435 1953)
• Replace transmission unit (Operation 3435 5553)
• Check Transmission Unit (Operation 3435 0199, 20 TU)
• Guided Fault Finding (Operation 0150 0060)
• Test drive before service (Operation 0121 0002, 10 TU)
• Test drive after service (Operation 0121 0004, 10 TU)

Required Parts or Tools

Technicians should consult ETKA/ELSA for the latest information and parts bulletins. Parts that may be required include:

• Fasteners, Bolts, Nuts, and Screws (as needed)
• Gear oil
• Gearbox (Quantity 01, if replacement is necessary)
• ODIS Tester (for diagnosis and road test procedures)

NHTSA ID: 11009978