2019-2025 Audi Door Handle Binding TSB 2060196/5

Owners of certain 2019-2025 Audi A6, A7, A8, Q8, and e-tron models may experience issues with exterior door handles that bind or do not return to their proper zero position. This Technical Service Bulletin (TSB) 2060196/5, released by Audi, provides a detailed repair procedure for technicians to address this concern.

Symptoms and Complaint Types

Customers may report several issues related to the exterior door handles. These include:

• "Central locking and/or door open warnings are displayed in the instrument cluster."
• "The doors are not closing and/or locking properly."
• "The door handles are binding and protruding."

Workshop findings confirm that the "Exterior door handles are binding and are not returning to the zero position." Other related complaint types noted in the TSB include the parking brake indicator display activating without cause, brake pedal operation display changing gear activating without cause, door lock warning display activating without cause, and the central locking system malfunction indicator activating without cause.

Technical Background

The root cause of the Audi door handle binding issue is attributed to material tolerances. Specifically, the door handle guide can bind within the door handle mounting bracket, preventing smooth operation and return to the zero position.

Revision History

This Technical Service Bulletin has undergone several revisions:

• Revision 5 (Current): Added MY24 and MY25 to the header, modified the production solution, added a picture procedure to the service instructions, and removed the diagnostic time table from the warranty section.
• Revision 4 (February 21, 2023): Added MY23 to the header.
• Revision 3 (July 29, 2021): Expanded the header to include MY19-22 A7 and A8, MY21-22 A6, Q8, Audi e-tron quattro, and Audi e-tron Sportback. It also added customer concerns to the condition section, modified the production solution, added a sanding procedure to the service instructions, and modified labor operations in the warranty section.

Repair Procedure Summary

The repair for the Audi door handle binding involves several steps performed by a qualified technician:

1. Initial Check: Verify the function of all door handles. They should return to the zero position without binding or jamming (Figure 1 illustrates a binding handle).
2. Handle Removal: Remove any affected door handles according to the Repair Manuals in Elsa.
3. Rib Removal: Use precision diagonal cutting pliers to remove door handle rib #1 and #2 from the pivot side of the mounting bracket, towards the front of the vehicle (Figure 2 shows the ribs before removal).
4. Surface Smoothing: After removing the ribs, ensure the resulting surface is smooth and free of protrusions (Figure 3 depicts the handle with ribs removed and a smooth surface).
5. Dimension Measurement: Use a vernier caliper to measure the dimension from the bottom edge of the door handle to the top of rib #3 (Figure 4 shows this measurement).
6. Rib Scraping: Scrape the top of rib #3 with a precision/utility knife until the dimension reaches 20.9 mm (~0.82 inches) (Figure 5 illustrates the scraping direction).
7. Rib Sanding: Sand down the top surface of rib #3 with sanding paper until the door handle measures approximately 20.6 mm (~0.81 inches) (Figure 6 shows the rib being sanded).
8. Guide Piece Replacement: Replace the door handle guide piece on the lock cylinder side, towards the back of the vehicle, with a new guide piece (Figure 7 shows the guide piece to be replaced).
9. Handle Reinstallation: Reinstall all door handles following the Repair Manuals in Elsa.
10. Functionality Verification: Confirm that all door handles are functioning normally.

Required Parts and Tools

Technicians will need the following parts and tools for this repair:

• Fasteners, Bolts, Nuts, and Screws: As needed per the Repair Manual (Refer to ETKA/ELSA).
• Guide Piece: Part Number 4N0837259 (Quantity: 01-04, as needed).

Warranty Information

For warranty claims related to TSB 2060196/5, the following details apply:

• Claim Type: This Technical Service Bulletin is informational only if the vehicle is outside of warranty.
• Service Numbers: 5711, 5811
• Damage Code: 0017 (for left 001 and/or right 002)
• Labor Operations and Time Units (TU):
  • Remove and reinstall front door handle: 5711 19XX (See SRT with associated operations)
  • Remove and reinstall rear door handle: 5811 19XX (See SRT with associated operations)
  • Remove and reinstall 2 front door handles: 5711 20XX (See SRT with associated operations)
  • Remove and reinstall 2 rear door handles: 5811 20XX (See SRT with associated operations)
  • Modify 1 front door handle: 5711 4999 (10 TU)
  • Modify 2 front door handles: 5711 5099 (20 TU)
  • Modify 1 rear door handle: 5811 4999 (10 TU)
  • Modify 2 rear door handles: 5811 5099 (20 TU)
• Claim Comment: Claims must include "As per TSB 2060196/5."

All warranty claims must comply with the Audi Warranty Policies and Procedures Manual and are subject to review or audit by Audi Warranty.

Important Notes for Owners and Technicians

When billing for this service, technicians must attach photos to DOC-IT that clearly show the complaint. These images must include the VIN and date, must not be edited, and should be in focus with sufficient light. It is crucial to mark the location of the problem and ensure no personal data (people, faces, license plates) is visible in the photo documentation.

NHTSA ID: 10248430