2015-2022 Audi Rear Suspension Rattle TSB 2038689/5

Symptoms

Owners of 2015-2022 Audi vehicles may experience a noticeable 2015-2022 Audi rear suspension rattle or clunking sound. The primary symptom reported by customers is that "clunking or rattling noises are heard from the rear suspension area when the vehicle is driven over bumps."

Technical Background and Diagnosis

This persistent noise is often attributed to a rear bump stop that was not fully inserted into the rear shock absorber mounting during the Pre-Delivery Inspection (PDI) process. An improperly seated bump stop can lead to the clunking or rattling noises as the vehicle drives over uneven surfaces. This Technical Service Bulletin, 42 21 46 2038689/5, addresses this specific condition.

Repair Procedure Summary

To resolve the 2015-2022 Audi rear suspension rattle, technicians will perform a specific service procedure. This involves ensuring the rear bump stops are correctly seated in the upper shock mounts.

1. The top of the rear bump stops must be cleaned thoroughly.
2. Tire mounting paste is then applied to the cleaned bump stops.
3. A specialized tool, SET900, is used to fully press the rear bump stops into the upper shock mounts. This tool provides the necessary leverage to properly seat the bump stops, preventing them from dislodging and causing noise.

This procedure ensures the bump stops are securely in place, eliminating the source of the noise. Visual aids in the TSB, such as Figure 2 and Figure 3, demonstrate the correct use of the SET900 tool and the difference between an improperly and properly seated bump stop.

Required Tools

The primary tool required for this repair is the SET900 bump stop installation tool. This tool was specifically developed by Audi to aid in the proper installation of rear bump stops. Audi dealers received one SET900 tool in November 2014, and additional tools can be purchased through the Audi Special Tools and Equipment Program.

Important Warnings and Information

Owners and technicians should be aware of the following:

• Dust Boot Caution: When lowering the vehicle, always ensure that the dust boot does not get caught on the top of the shock.
• Warranty Coverage: This Technical Service Bulletin 2038689/5 is informational only and is not applicable to any Audi Warranty. Owners should discuss potential costs with their dealership.
• Superseded Bulletin: This bulletin, dated August 2, 2021, supersedes Technical Service Bulletin Group 42 number 20-44 dated May 13, 2020. The revision history indicates updates to added model years and required parts and tools.

Additional Resources

A video demonstrating the use of the SET900 tool is available online. This video can be accessed via a QR code provided in the bulletin or directly through the link: https://audi-external.kzoplatform.com:443/swf/player/286. Further information on viewing TSB videos can be found in TSB 2039206, titled "00 Viewing TSB videos."

NHTSA ID: 10199925