Aluminium Fatigue

br1anuk

Member
I called into Liverpool Audi and a lovely assistant from the service department took some photos of the cracks on the front door hinge area after looking up the TPL on the audi database.
She promised to get back in touch within 48hrs.
Fingers Crossed.

Brian.
 

John H

Member
Hello, it's me again, not posted for a while. I had hoped I wouldn't have to contribute to this thread, but it looks like old faithful may have developed the dread door cracks after all. I just noticed a bit of wind whistle from the drivers door, and on investigation I found that the top of the door was no longer sealing properly. A further check of the hinges this morning suggests there is a crack, so I have a few questions.

Is the crack likely to be the cause of the sealing problem, and the wind whistle?
What is the current situation with the warranty? Has it ended, or do I still stand a chance?

I'm now off to read through this enormous thread all over again to find the salient details, but if anyone would care to point out where I can find this TPL I'd be much obliged.

Cheers

John H

doorhinge1r.jpg
 
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murdo

Admin Team
Hi John. The warranty was lifetime however there's been example of it not being honoured and dealers saying the campaign code has expired. I had warranty work done for an unassociated matter at Glasgow Audi in the last couple of years. I spoke to the estimator about this door cracking issue and he was aware of it.

Is Edinburgh Audi aluminium approved repairer? Just wondering as this will determine if they do much work on the A2. If not I'd give Glasgow Audi body shop a ring.

I'd ponder that with a fair crack like in the photo it may have affected the door alignment but I've no competence to give you a qualified answer on this.

You can buy the repair kit for the hinge as well. Tony at A2 cars did his own repair with this kit but Milton Keynes a bit far from bonnie Scotland!

Good luck.
 

Birchall

Dick Chown Award 2016
Hi,

Firstly, it is as likely to be a loose or badly adjusted hinge as the common crack problem.

So firstly check for loose hinge bolts. If they are loose the top of the door can move outwards breaking the seal between the rubber and the door frame. Hence the wind noise.

So check out the hinges first before you spend any money.

Steve B
 

John H

Member
Thank you both for the speedy responses. Firstly I use Perth Audi where I have been a customer for years, and to date they have never failed me. They replaced the tailgate a while back under the 12 year warranty without quibble, so I am hoping they will honour this one too. Car is a 2008, with now 150,000 miles up.

I cleaned up the hinge area this morning, but to my eye at least I can't see (or feel) any looseness, and there is no evidence that the hinges have moved.

My plan is to take the car into Perth Audi and ask them to diagnose the problem, but as usual I like to be full forearmed ... it makes a world of difference if you already know the answers before you pose them the questions!
 

murdo

Admin Team
TPL in this post:

Hi all, I'm new to this forum so apologies if this is old news... Just reading about aluminium fatigue and some other associated posts about creaky and cracked A2 door hinges...My drivers door was making a terrible cracking noise when opened and closed so I did some hunting around on the web and found it appeared to be a common issue. I spoke to my local dealer (Norwich Audi) who at first claimed to have not heard of such a problem. I then informed them of an internal Audi bulletin I'd seen on another forum, emailed it to them, and within the same day the parts were on order without my car even being seen!!

I had to wait about 2 weeks for the parts to arrive and Audi have just had the car in for the repairs for 4 days, but all seems well again with my newly replaced hinges! And I didn't have to pay a penny and was given a courtesy car so pleased with service.

Here is the original link and bulletin I sent the main dealer. Hope it is useful to you if your A2 is creaking at the seams!

-------------------------------------------------------------------

Routine durability monitoring by Audi AG has identified a minor cosmetic flaw in the door
hinge of the Audi A2 (model year 2000-2005).
It has been discovered that the hinge can be susceptible to cracks on the outer non-structural
skin.

To some customers this may lead to concern that the structural integrity has been compromised – this is not the case.
Should you receive any customer enquiries relating to this characteristic please advise them that extensive testing of affected hinges by Audi AG has confirmed that their performance and longevity are in no way reduced by these surface cracks.

Replacement doors have been modified since September 2007.
Audi AG have produced a Technical Problem Solution (TPL) which has been published on ELSA -
TPL number 2016707/1. This TPL includes details of how to claim the cost of the repair. Please
note that all vehicles are covered - even if out of warranty - and so customers should not becharged.

However, we do not expect to be in a position to have all the required parts in stock at Dordon until
mid-March. The two part numbers currently unavailable are the kits 8Z0 898 021 and 8Z0 898
022. Please postpone all repairs until all the parts are available. The other parts required are:
• 8Z0 837 349C
• 8Z0 837 350C
• 8Z0 868 243
• DA 001 730 A2
• D 001 001
• D 009 401 04
• N 903 675 03
• N 101 154 04
• 8Z0 898 021 (currently unavailable)
• 8Z0 898 022 (currently unavailable)
As soon as all parts are in stock we will issue a further announcement.

http://www.tyresmoke.net/forum/audi-a2/106191-door-hinge.html#post1293516
 

John H

Member
Just looked again more closely, and there is indeed a very small bit of movement where the hinge bolts onto the door. Thanks for the heads up Birchall.

Is that a Torx fitting? I haven't got one, Anyone know what size I need?

Thanks in advance.
 

Birchall

Dick Chown Award 2016
As for the wind noise, my money would NOT be on it being related to the crack. The door would need to have moved a fair amount to let in that kind of wind noise.

Has the door been dismantled in recent times? The door window frame can be put back in slightly out of line if you are not careful.

I agree that the crack needs to be resolved of course, but I still think the wind noise will be due to adjustment, but that is just my "remote" opinion.

While repairing the crack they will (hopefully) correctly align the door anyway, so you should be fine.

I hope Audi resolve this for you without hassle (I am sure they will)
Steve B
 

John H

Member
Steve, thanks so much for the input, as more careful examination has shown that the top bolt is slightly loose and the door is moving relative to the hinge, so for the moment at least I now know what the problem is. All I need to do now is buy, borrow or steal the necessary torx headed tool to fix it!

Damn, I'd forgotten what a great forum this is! :eek:
 

the grim reeper

A2OC Donor
Hi John to me when you blow your photo up this doesn't look like a crack it looks like blistering under the paint when I get my Laptop on later i will see if I can find the photo of mine

Cheers Phil
 

John H

Member
Hi John to me when you blow your photo up this doesn't look like a crack it looks like blistering under the paint when I get my Laptop on later i will see if I can find the photo of mine

Cheers Phil
Agreed, very hard to tell exactly what it is. My guess is that it is a crack of some sort but that it has been there for a long time, thereby allowing the paint to blister. You can certainly feel something with your finger though.

Meanwhile a trawl round Halfords and a few tool shops failed to turn up any torx fittings. I have managed to temporarily tighten it with some mole grips, and I'll get the garage to do it properly and re-align the door, and also check the crack.
 

murdo

Admin Team
If you intend keeping the car long term John I'd be tempted to have the job done if Perth Audi will process it for you.

Memory serving it's new hinges fitted with strengthening plates epoxied to the inner surfaces so it's a peace of mind for the future job. The mark above your hinge doesn't look like the aluminum oxidation I've seen on panels as it's a defined line. See what they say and hopefully it'll be good news for you. I recall you saying about Perth before and they do have a great reputation for customer service.
 
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murdo

Admin Team
Hi John to me when you blow your photo up this doesn't look like a crack it looks like blistering under the paint when I get my Laptop on later i will see if I can find the photo of mine

Cheers Phil
Agreed Phil however there's what looks like a small crack at top right corner of the hinge maybe 5mm long at a 30 degree or so angle.

I'd reckon this is a when not if issue so 7 years on another hats off to Skipton for raising this with Audi UK and providing the evidence to secure the lifetime warranty.
 
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spike

Well-Known Member
I've not read every post but ref (496), I think it may be a struggle to get repairs done now under the goodwill scheme. One of the key posts (411) by Skipton may however help the cause for anyone discussing this with their dealer. It also provides all the part nos if considering paying for a repair by an independent garage.

Talking of which, Tony from A2 Cars has already performed surgery on his own car (I think) and would be the ideal person to contact. I'm sure there were pictures of the completed job but I'm struggling to find them.

Cheers Spike
 

John H

Member
If you intend keeping the car long term John I'd be tempted to have the job done if Perth Audi will process it for you.

Memory serving it's new hinges fitted with strengthening plates epoxied to the inner surfaces so it's a peace of mind for the future job. The mark above your hinge doesn't look like the aluminum oxidation I've seen on panels as it's a defined line. See what they say and hopefully it'll be good news for you. I recall you saying about Perth before and they do have a great reputation for customer service.
I have no plans to get rid of the A2 at the moment. I still love it, and even after 150,000 miles it still feels good. More to the point there is nothing on the market to tempt me. Perhaps a BMW i3, but not in its present form (My thoughts here http://www.arthurlea.com/Stories/BMWi3/index.htm ) So on that basis it is worth me trying to get the doors looked at and any issues resolved.

Error ... earlier I said it was a 2008 car, In fact I bought it in 2008, it is of course a 2005 car.

Thanks everyone for all the advice.

John H
 

Birchall

Dick Chown Award 2016
http://www.a2oc.net/forum/showthread.php?19893-If-you-can-do-one-thing-today

Hi John,
check the door side as well as I found mine lose.
ATB
Roy
Yes, Roy is right, the bolt heads on the "door side" of the hinge are quite well hidden and covered by the foam rubber and they are often loose and go unnoticed..

As suggested the bolts can't be tightened up with a long "keys" so try to get the "bit" that goes into a socket and just use that bit by itself. Find a ring spanner that fits the other end of the bit. This is the only way you will be able to tighten the bolts.

Steve B
 
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Doug S

Member
Hello, I'm relatively new to this forum having bought my A2 (1.4 TDI 90) just last year. I did add a post previously for many warning lights coming on and through reading all the posts have managed to work out the problem (engine temperature sensor) and replaced myself.... you could build a A2 from scratch with the info in this forum. I did take it for a diagnostic at Bosch service centre and came back with a list of issues with a repair bill of £1500... and most of it was speculative on the codes. Had a friend who's into TT's run his VAG diagnostic thingy on it and we narrowed it down to the sensor and glow plugs.... much cheaper and done now.
However, back to this thread, I read it and my heart sank as I noticed my door feeling a bit less secure and has dropped a few MM. Went and checked my driver door and sure enough its cracked where the hinge buts up against the door, its not visible as some of the pics in this thread but feel it rising up from the hinge with my fingers. I am in Fife, Scotland so Perth is my closest dealer. So.... is there anypoint i'm me going to them with the age of my car? I see Murdo has mentioned its a lifetime warranty, so, do I have a hope?
 
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