Body - Outer Door Seals Are Loose
57 Outer door seals loose57 11 61
2027494/2
October 31, 2011.
Supersedes Technical Service Bulletin Group 57 number 11 - 56 dated September 7, 2011 for reasons listed below.
Affected Vehicle
Condition
The outer door seals have become partially detached
Technical Background
Loss of adhesion between the door structure and door seal due to a flaw in the attachment process in production.
Production Solution
No changes to production have been made, as no issue has been identified.
Service
Note:
Audi of America is requesting your cooperation in supplying us with technical information regarding this condition. Before repairing the door seals using the procedure in TSB 2019733, please complete the door seal survey at:
http://www.surveymonkey.com/s/B8DoorSealSurvey
Answer the questions regarding the extent and location of detachment of the door seals from the tables shown below:
Answering these questions in the survey will help us gather information to implement further production improvements. After the survey is completed, continue with any necessary repairs. The procedure for repair follows.
In cases where the outer door seal has become partially detached, it may not be necessary to replace the outer door seal. Seals can be reattached provided they are not damaged, have not been previously repaired or previously reattached, and the detachment length does not exceed 10cm.
1. Inspect all four doors.
^ All undamaged, previously unrepaired or loose seals with a detachment length less than 10 cm will be repaired. Complete steps 2-10 below to repair the door seals.
^ If the door seal is damaged, has been previously repaired or previously reattached or detached greater than 10 cm, replace the door seal according to the repair instructions in Elsa Web >> Body >> Body Exterior >> 57 Front Doors, Central Locking System >> Removal and Installation >> Doors � Door Seals.
^ In the case of a rear door seal replacement, refer to Elsa Web >> Body >> Body Exterior >> 58 Rear Doors >> Removal and Installation >> Rear Door >> Door Seals.
Note:
In addition to the repair manual instructions for replacing the door seals observe the following: Thoroughly clean the area of seal attachment with plastic cleaner D 009 401 04. Allow the area of seal attachment to dry completely (at least 5 minutes). Apply bonding agent D 355 205 A2 using a D 009 500 25 applicator to the seal attachment area. Allow to dry an additional 5 minutes.
If repairing the door seals, proceed as follows:
2. Ensure that the temperature of the door and outer door seal are not cooler than 70°F (21°C). This is vital to ensure optimum adhesion of the outer door seal.
3. Thoroughly clean the bonding surfaces of the doors to be repaired with plastic cleaner D 009 401 04. Allow the bonding surfaces to dry completely (at least 5 minutes). The bonding surfaces must be dry and free of any dust, grease, silicone or any other similar contaminant that might compromise the adhesion.
4. Apply bonding agent D 355 205 A2 using a D 009 500 25 applicator in the area to be bonded. Allow the treated surface to dry an additional 5 minutes.
5. Thinly coat the outer door seal with rubber profile adhesive D 477 KD1 A2 in the area that has become detached.
6. Press the door seal lightly to the door surface and then detach it again (Figure 3). This ensures that the glue is distributed as evenly as possible on the surfaces to be bonded.
7. Allow the now detached area to dry for 5 minutes.
8. After this time attach the seal firmly to the door surface. Roll over this area several times with special tool 3356 (or equivalent).
9. Apply force to the seal with the 3356 only at the base of the seal (Figure 5, 3).
10. Remove any residual adhesive that may be visible with adhesive remover D 002 000 A2.
Tip: The repaired door should not be closed for two hours. During this time, any freshly glued surfaces should not be tested by pulling on the seal to see if they have bonded.
Warranty
Required Parts and Tools
Additional Information
All parts and service references provided in this TSB are subject to change and/or removal. Always check with your Parts Department and service manuals for the latest information.