Aluminium Fatigue

Ian S said:
Thanks Mike,

Could you give me a few pointers on how best to remove the door card, without damaging anything. So is just the rivet that has gone or should I be on the look out for the "fatigue thing"? Oh and any ideas on what diameter/length bolt will be requires please?

Thanks
Click to expand...

There's 3 torx screws that hold on the card - 1 behind the tweeter grille and 2 under the armrest/door pull.

Undo these and then starting at the bottom, jerk the card away from the metal (sounds drastic, but it's the only way to free off the clips). Once all clips removed, lift up the card from the window sill and unhook the bowden cable to the door handle and unclip the electrics to release the card entirely.

The bolts you'll need are about 10-12mm long and about M5-M6. Use nylocks if you can to prevent future movement.

You should look out for the cracking, which emanates from the top of the door hinge (the place where the 5mm thick top hinge meets the main door pressing) whilst you are doing the rest of the work. It almost seems that passenger doors are affected more than the more often used drivers door.

Cheers,

Mike
 
Scince I have a brand new unused but painted door at home, I will show you some images, what it is about and how it must look if there is no crack.
I also took photos from the inside. I uploaded these to the german forum but think I will show you. The problem is, that the rivets around the hinge are too far away of it. So there can be this movement which causes the cracks.
 
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Interesting Erstens. Thanks for the pics. The last one, at the bottom left hand corner does seem to show some allignment lines on the bodywork behind the hinge.
 
Yes, you are right and that is why I show this.

Here the inside where you see the thicker sheet metal behind the visible sheet metal (at the inside behind the hinge).
 
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erstens said:
Scince I have a brand new unused but painted door at home, I will show you some images, what it is about and how it must look if there is no crack.
I also took photos from the inside. I uploaded these to the german forum but think I will show you. The problem is, that the rivets around the hinge are too far away of it. So there can be this movement which causes the cracks.
Click to expand...

Thanks Erstens for the pictures, I have had a good look at the hinges and it would appear that it's just the rivets that have failed as Mike suggests.

Cheers Ian
 
cracks above hinges

I have a 2004 1.4 model which only has 11500 miles on the clock and I have found cracks above both front door hinges. I have booked it in to be looked at on Tuesday 25th by Newcastle Audi who don't appear to know about the problem so I'll see what happens and feed back.
Mike, I see from this thread that Audi will repair the problem free of charge? Is there a single reference, audi bulletin or contact, etc we can quote to the dealers to ensure this is the case?
Albiej :)
 
Albiej said:
I have a 2004 1.4 model which only has 11500 miles on the clock and I have found cracks above both front door hinges. I have booked it in to be looked at on Tuesday 25th by Newcastle Audi who don't appear to know about the problem so I'll see what happens and feed back.
Mike, I see from this thread that Audi will repair the problem free of charge? Is there a single reference, audi bulletin or contact, etc we can quote to the dealers to ensure this is the case?
Albiej :)
Click to expand...
All franchised Audi dealers have been issued a bulletin about the problem and the repair process, so they should know about it already.

If they continue to play dumb, get me a contact name (pref. service manager) and I'll get things straightened out with Audi UK.

Cheers,

Mike
 
How much?

I visited Newcastle Audi today who's staff were very helpful, however....
the technician could see cracks above the hinges on both doors but could not ascertain if they were cracks in the paint or in the metal. In order to check this properly they would have to remove both doors at a cost of £154 to myself which if successful could claim back from Audi Uk.
I declined pending contact with Audi.
Mike,the Service Manager is a Steve Clark and I have not contacted Audi at this time as I did not want to affect any relationship you have with Audi.
Could you chase it up for me at all? :)
 
Had a phone message today from Birmingham Audi to say they have not yet received the replacement hinges for my doors but will let me know when they have them in.
 
I also had a call yesterday from my VW garage (the next door same-owner Audi does not have a bodyshop - probably my good fortune) with the same information.

Was also informed that since my last call to book the vehicle in for the work in Feb, they had received a further bulletin from Audi confirming that the work would be covered by warranty, just as Mike had assured everyone - important to me as I have a 2001 car.
 
Look at my third image.The crack is beginning from the top end of the hingue at the sheet metal on the door. Right here, were you don't see any crack, because it is a brand new door (and than go to the first page and see my images there or on the second page)
The first image is with the cracks. The second without but marked, were they appear to happen.
(I could not find the images on the first or second page in this thread)
 
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If you open the front doors and run the pad of your finger along the top of the top hinge plate, the crack (if present) will be felt as a seam or small lump on the door pressing.

If you take a look in the earier pages of this thread, there's loads of photos and links that illustrate the issue better than words can.

Cheers,

Mike
 
Links yes, but I myself could not find any image in this thread with cracks, only the new door design... Maybe some are gone... :)

Edit: The Links did not work for some reason, so I uploadet the images on page 1 in this thread.
 
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Just checked my doors on my 2001 A2 1.4SE. In error I had been looking at the door casing eg body shell "Duh". Only realised from pics it was on the door. Low and behold cracks on drivers door , passenger door clear. Im off to Blackburn (Lookers) Audi tommorrow, anyone been to them so far ?

Steve
 
message for Erstens

Hi ( and please ignore this if you know already ) if you look at the subject description (when its in the new posts area ), you see a faint "paperclip" sign eg attachments to the right hand side of the description. Just click on this and all the photos for this thread are there. I think yours are certainly there.

Hope this helps

Steve
 
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