0CJ Averia C05ED00 y C05ED Problema Diferencial Trasero Sistema Ultra Quattro
0CJ Averia C05ED00 y C05ED Problema Diferencial Trasero Sistema Ultra Quattro
39 21 42 2051558/6 March 2, 2021. Supersedes Technical Service Bulletin Group 39 number 20-39 dated
December 10, 2020 for reasons listed below.
A4, A4
allroad, and 2018 All Quattro Ultra
S4
A5, A5
Cabriolet.
A5
Sportback,
2018 All Quattro Ultra
S5, S5
Cabriolet,
and S5
Sportback
A5, A5
Cabriolet.
A5 A000001 –A073698
Sportback,
2019 Or Quattro Ultra
S5, S5
Cabriolet, N000001 - 010733
and S5
Sportback
Condition
REVISION HISTORY
5 12/10/2020 Revised Service (Updated which ODIS test plan results to follow)
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4 08/22/2020 Revised Service (Updated instructions to reuse springs)
Revised Required Parts and Tools (Updated Vise part number)
Customer states:
The message "four-wheel-drive malfunction" is sporadically shown in the instrument cluster.
Workshop findings:
The following DTC is logged in the all-wheel-drive control module, J492 (address word 0022):
DTC C05ED00 (4WD/AWD Clutch "B" Stuck Engaged) with symptom code 29725.
Technical Background
Quattro Ultra shift fork inside the rear differential is
worn/faulty (Figure 1).
Production Solution
Improved material in production.
Page 2 of 17
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America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted
in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the
publisher.
Service
Proceed as follows:
Complete the ODIS test plan for the DTC C05ED00 (4WD/AWD Clutch "B" Stuck Engaged) completely
according to Guided Fault Finding to rule out other reasons for the restricted function and to avoid an
unnecessary parts replacement:
If the result of the test plan leads to replacing the rear differential or finds no defect, perform a short test
drive. If the same DTC returns after the test drive with the same symptom, the shift fork inside the rear
differential is at fault and must be replaced. Perform the repair as follows. Do not replace the complete
differential.
If the result of the test plan leads to replacing or repairing a different part (The All-Wheel Drive Clutch,
Driveshaft Speed Sensor G970, All Wheel Drive Clutch Actuator 2 V623, or any other part), follow the Guided
Fault Finding repair advice and this TSB does not apply.
1. Drain the oil of the rear differential according to the repair manual.
Tip: Although there are instructions available in the Elsa repair manual to perform this repair, the tools
utilized in Elsa have never been required tools. Our records indicate that few dealers have procured them as a
result. The repair shown in this TSB uses tools that are minimum required tools and one tool that will be auto
shipped to Audi dealers shortly. If you are missing a tool for this repair, please order it and continue with the
repair.
At the time of publishing this TSB, we have enough tools in stock to handle these repairs/orders. If the web site
shows no availability of a tool that you require, please call SBS directly at 1-800-892-9650 as they may have
stock that is not showing on the site.
3. Place the differential on a workbench and remove the All-Wheel Drive Clutch Actuator 2 -V623- according
to the repair manual.
Page 3 of 17
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America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted
in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the
publisher.
5. Mount the side carrier as shown below (Figure
3) to the VAS6095 using T40206, T40206/1A,
one long slotted arm from the VAS6095, 3350/2
(Figure 4 and Figure 5), three M10 flat washers
2mm thick each (Figure 5), one M10 x 1.5 x70
bolt (Figure 4 and Figure 5), and one M12 x 1.5
x 38 bolt (Figure 4).
Page 4 of 17
© 2021 Audi of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Audi of
America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted
in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the
publisher.
Figure 4. Mounting detail. Figure 5. Mounting.
5a. The passenger side differential mount attaches to the T40206/1A at hole #6 and the long slotted arm of the
VAS6095 attaches to threaded hole 5A using one of the M12 x 1.75 x 40 bolts from the VAS6095
engine/transmission stand (Figure 7). Alternately the long slotted arm of the VAS6095 can attach to
threaded hole 5B with any M12 bolt and a nut (bolt must be 50mm or longer).
Page 5 of 17
© 2021 Audi of America, Inc.
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America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted
in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the
publisher.
Figure 6. Mounting. Figure 7. Mounting.
Page 6 of 17
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America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted
in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the
publisher.
7. Remove the gear carrier (Figure 9, position 1
and Figure 10). During this step, guide the shift
fork out of the clutch module (engagement
collar), then remove the shim (Figure 9, position
2).
Page 7 of 17
© 2021 Audi of America, Inc.
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America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted
in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the
publisher.
8. Remove the springs and save them for
reinstallation (Figure 11, position 1).
Remove the roller sleeves (Figure 11, position
2).
Page 8 of 17
© 2021 Audi of America, Inc.
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America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted
in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the
publisher.
10. Insert the pins (Figure 13, position 1) into the
holes of the gear carrier.
11. Insert the new shift fork from the repair kit
(Figure 14, position 2) into the gear carrier, and
in doing so pay attention to the right installation
position.
Page 9 of 17
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America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted
in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the
publisher.
12. Pressing in the bearing pin with a vise using the
plastic or brass soft jaws:
Tension the gear carrier (Figure 15, position
2) and pin -5- as shown into the vise (Figure
15, position 4).
Push in the pin (Figure 15, position 5) so far
that it is flush with the inner side of the shift
fork (Figure 15, position 1).
Repeat the procedure on the other side.
Check if the shift fork (Figure 15, position 1)
can be swiveled with ease.
Figure 15. Pressing a pin with a vise.
Page 10 of 17
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America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted
in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the
publisher.
12b Insert the T10172/9 with the M8 flange nut as
. shown and the collared nut provides a solid
surface to press the pin against (Figure 17).
Page 11 of 17
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America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted
in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the
publisher.
13. Apply a small amount of assembly grease to the
pins for the bushing and install the new
bushings from the repair kit (Figure 19, position
2).
If the coupling sleeve (Figure 21, position 3) is easily removed from the shaft, remove it, and insert it into
the gear carrier (Figure 21). Pay attention that the sleeves (Figure 21, position 1) engage in to the groove
of the coupling sleeve (Figure 21, position 3).
Insert the gear carrier (Figure 20, position 1) into the housing together with the coupling sleeve. Pay
attention that the shock absorber (Figure 20, position 2), and the centering pin is correctly positioned to the
housing (Figure 20, arrow).
If the coupling sleeve (Figure 21, position 3) is difficult to remove from the shaft you can raise it up the
shaft and install it into the clutch module and install the gear carrier paying attention to the steps above.
Page 12 of 17
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America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted
in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the
publisher.
15. Remove the magnet (Figure 22, position 1),
clean it, and re-insert.
Page 13 of 17
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America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted
in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the
publisher.
17. Reassemble the case halves.
19. Install the All-Wheel Drive Clutch Actuator 2 -V623- per the repair manual.
20. Install the differential into the vehicle per the repair manual.
21. Fill the differential with oil per the repair manual.
Page 14 of 17
© 2021 Audi of America, Inc.
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America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted
in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the
publisher.
Warranty
Claim Type: 110 up to 48 Months/50,000 Miles.
G10 for CPO Covered Vehicles – Verify Owner.
If the vehicle is outside any warranty, this Technical Service Bulletin is informational
only.
Labor Operations: AWD final drive assembly remove + reinstall 3988 19XX See SRT with
associated
operations
Some models have associated labor See Elsa See SRT with
operations for remove + reinstall AWD final associated
drive assembly depending on their equipment operations
See ETKA Fasteners, Bolts, Nuts, and Screws as needed per the See ETKA/ELSA
Repair Manual
Page 15 of 17
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America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted
in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the
publisher.
G 060190A2 Axle oil 01
VAS251001 with
VAS251001/2
Two Arm Puller
or
T10040 with T10040/2
Additional Information
All parts and service references provided in this TSB (2051558) are subject to change and/or removal.
©2020 Audi of America, Inc. All rights reserved. Information contained in this document is based on the latest
information available at the time of printing and is subject to the copyright and other intellectual property rights of
Audi of America, Inc., its affiliated companies, and its licensors. All rights are reserved to make changes at any
Page 16 of 17
© 2021 Audi of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Audi of
America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted
in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the
publisher.
time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in
any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these
materials be modified or reposted to other sites without the prior expressed written permission of the publisher.
Page 17 of 17
© 2021 Audi of America, Inc.
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America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted
in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the
publisher.