Rear Sport Diff Leak: Audi says must be one drop/second?!?!

[USAFS4]

So tuning shop notices some leakage from my rear sports diff. Take to dealer and tech tells service writer who tells me that Audi defines a LEAK as something like "one drop per couple of seconds." WTF?!?! Anyone else heard of this? I forgot the exact number of seconds per drop, but does it F'ing matter.

I'm going to contact another dealer to double check but if this is true holy F; Audi is just ensuring they don't have to replace a poor design before warranty ends.

Anyone have a real sport diff failure yet because fluid got to low? Wonder how many miles on average that will take. Probably should just figure a $9k repair at some point during the life of the car.

[nacelle]

That's a plan.... interested in hearing more about this.

yikes!

[MrFunk]

LOL -

A leak is a way (usually an opening) for fluid to escape a container or fluid-containing system, such as a tank or a ship's hull, through which the contents of the container can escape or outside matter can enter the container. Leaks are usually unintended and therefore undesired.

So if it was unintended for fluid to be escaping the rear diff through a seal or whatever it's leaking from - then it's defined as a leak. If it's covered under warranty you'd think the dealer would be happy to take on such a nice big job!

[helix139]

There is a TSB on leaking seals on the diff. Do you have an actual dripping leak or simply grease getting slung on the underside and your axles? You should be able to search and find the TSB number fairly easily and reference that when going to the dealership.

[levigarrett]

Leaky SD has been discussed here recently. Do a search.

[USAFS4]

Leaky SD has been discussed here recently. Do a search.

I know it has been discussed, but my dealer basically said that they are not going to address it unless it is dripping. I believe most threads have discussed material being slung into the chassis. I have not looked at myself, but my tuning shop thought it was important enough to mention.

[LYKUNO]

Here's a pretty lengthy thread (with pics and details) about the leaking sports diff issue, and the TSB that resolves it. I had the problem on our 2011 - barely dripped on the garage floor, but what got slung onto the exhaust system would make the garage smell like hot oil whenever it was parked. The dealer took care of it without any hassle.

http://www.audizine.com/forum/showth...ight=leak+diff

Here's a description of the fix on the invoice of a repair ...

Cause: LEAKING

39881903 AWD FINAL DRIVE ASSEMBLY REMOVE + REINSTALL
3817 W40 3.70
1 D-454-300-A2 SEALANT
2 4F0-501-269 PROTEC CAP
12 N-900-972-04 BOLT
42212050 DRIVESHAFT REMOVE + REINSTALL
3817 W40 1.30
42242099 REMOVE AND INSTALL 2 CONSTANT VELOCITY JOINT CAPS
3817 W40 0.20
01210004 TEST DRIVE
3817 W40 0.10

FC: 422950002002
PART#: 4F0-501-269

DESCRIPTION: 3522 INSUFFICIENT SEALANT ON LEFT AND RIGHT CV JOINT PROTECTIVE CAPS INSPECTED SPORT DIFF AND FOUND FLUID LEAKING FROM LT AND RT CV JOINT CAPSR. R+I FINAL DRIVE SPORTS DIFFERENTIAL, R+I LEFT AND RIGHT REAR DRIVESHAFTS, R+I LEFT AND RIGHT CV JOINT PROTECTIVE CPS, APPLY SEALANT TO LEFT AND RIGHT CV PROTECTIVE CAPS, ROAD TEST VEHICLE FROM X TO Y MILES, ALL DIAGNOSTICS AND REPAIRS PERFORMED PER TSB # 2026049/1

If your dealer refuses to fix it because it's "not dripping enough", I'd recommend contacting AoA or finding a different dealer.

[USAFS4]

Here's a pretty lengthy thread (with pics and details) about the leaking sports diff issue, and the TSB that resolves it. I had the problem on our 2011 - barely dripped on the garage floor, but what got slung onto the exhaust system would make the garage smell like hot oil whenever it was parked. The dealer took care of it without any hassle.

http://www.audizine.com/forum/showth...ight=leak+diff

Here's a description of the fix on the invoice of a repair ...

Cause: LEAKING

39881903 AWD FINAL DRIVE ASSEMBLY REMOVE + REINSTALL
3817 W40 3.70
1 D-454-300-A2 SEALANT
2 4F0-501-269 PROTEC CAP
12 N-900-972-04 BOLT
42212050 DRIVESHAFT REMOVE + REINSTALL
3817 W40 1.30
42242099 REMOVE AND INSTALL 2 CONSTANT VELOCITY JOINT CAPS
3817 W40 0.20
01210004 TEST DRIVE
3817 W40 0.10

FC: 422950002002
PART#: 4F0-501-269

DESCRIPTION: 3522 INSUFFICIENT SEALANT ON LEFT AND RIGHT CV JOINT PROTECTIVE CAPS INSPECTED SPORT DIFF AND FOUND FLUID LEAKING FROM LT AND RT CV JOINT CAPSR. R+I FINAL DRIVE SPORTS DIFFERENTIAL, R+I LEFT AND RIGHT REAR DRIVESHAFTS, R+I LEFT AND RIGHT CV JOINT PROTECTIVE CPS, APPLY SEALANT TO LEFT AND RIGHT CV PROTECTIVE CAPS, ROAD TEST VEHICLE FROM X TO Y MILES, ALL DIAGNOSTICS AND REPAIRS PERFORMED PER TSB # 2026049/1

If your dealer refuses to fix it because it's "not dripping enough", I'd recommend contacting AoA or finding a different dealer.

Thanks. This is helpful. And I think my dealer may lose my business. It will be interesting to see what another dealer says. Won't be able to get another dealer to look at it for 2 weeks. I'll post and update then.

[LYKUNO]

Almost forgot, here's a link to a docx-formatted description and diagram for the TSB, illustrating the parts involved:

https://docs.google.com/file/d/1mOnc...tJf/edit?pli=1

[USAFS4]

Almost forgot, here's a link to a docx-formatted description and diagram for the TSB, illustrating the parts involved:

https://docs.google.com/file/d/1mOnc...tJf/edit?pli=1

Awesome! Thnx. By the way mine is a 2012. So guess this updated sealer may have not made it into early model 2012s.