2022-2025 Audi Door Handle Binding TSB 2060196/5

Audi has released Technical Service Bulletin (TSB) 2060196/5 to address a common issue where exterior door handles on certain models may bind, protrude, or fail to return to their normal zero position. This problem can lead to various symptoms, including warnings related to central locking and improper door closure. This TSB provides a detailed repair procedure for technicians to correct the issue.

Symptoms

Owners of affected Audi vehicles, including the Audi e-tron door handle binding issue, may observe the following symptoms:

• Exterior door handles that do not return to the zero position after being operated.
• Door handles that feel stiff, bind, or protrude from the vehicle body.
• Warning messages in the instrument cluster related to central locking or doors being open.
• Difficulty with doors closing or locking properly.

Technical Background

The root cause of the Audi e-tron door handle binding and similar issues across other models is attributed to material tolerances. Specifically, the door handle guide can bind within the door handle mounting bracket, preventing the handle from operating smoothly or returning to its fully closed position.

Audi's production solution for new vehicles involves an optimized component design. For existing vehicles experiencing this issue, a specific service procedure is required.

Repair Procedure Summary

To resolve the door handle binding, technicians will perform a multi-step repair:

1. Initial Check: Verify the functionality of all door handles, ensuring they return to the zero position without binding or jamming.
2. Door Handle Removal: Remove the affected exterior door handles following the instructions in the Elsa repair manuals.
3. Rib Modification: Using precision diagonal cutting pliers, technicians will remove door handle ribs #1 and #2 located on the pivot side of the mounting bracket, towards the front of the vehicle. The resulting surface must be smooth.
4. Rib #3 Adjustment: A vernier caliper is used to measure the dimension from the bottom edge of the door handle to the top of rib #3. The top of rib #3 is then scraped with a precision/utility knife until the dimension reaches approximately 0.82 inches (20.9 mm).
5. Sanding: The top surface of rib #3 is further sanded down with sanding paper until the measurement is approximately 0.81 inches (20.6 mm).
6. Component Replacement: A new door handle guide piece (part number 4N0837259) is installed on the lock cylinder side, towards the back of the vehicle.
7. Reinstallation and Verification: The door handles are reinstalled according to Elsa repair manuals, and their normal function is verified.

Required Tools or Parts

To perform this repair, technicians will need the following specific items:

• Part Number: 4N0837259 (Guide Piece, quantity 01-04 as needed)
• Fasteners, Bolts, Nuts, and Screws as specified in ETKA/ELSA
• Precision diagonal cutting pliers
• Vernier caliper
• Precision/utility knife
• Sanding paper
• Elsa (Audi's electronic service information system for repair manuals)

Warranty Information

For vehicles still under warranty, this repair should be covered. The TSB specifies the following codes for warranty claims:

• Service Numbers: 5711, 5811
• Damage Code: 0017 (for left 001 and/or right 002)
• Labor Operations: Specific labor operations are provided for removing, reinstalling, and modifying one or two front/rear door handles (e.g., 5711 19XX, 5811 19XX, 5711 20XX, 5811 20XX, 5711 4999, 5811 4999, 5711 5099, 5811 5099).

If the vehicle is outside of warranty, this Technical Service Bulletin serves as informational guidance. All warranty claims must adhere to the Audi Warranty Policies and Procedures Manual.

Owner Action

If you own a 2022-2025 Audi model and are experiencing issues with your exterior door handles binding, protruding, or not returning to the zero position, it is recommended to contact your authorized Audi dealership. Inform them about the symptoms you are observing, such as the Audi e-tron door handle binding, and mention Technical Service Bulletin 2060196/5. The dealership technicians will be able to diagnose the issue and perform the necessary repair as outlined in the TSB.

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NHTSA ID: 11023737