A few months ago my car started making a popping noise when I would accelerate, brake, turn, hit bumps and some times even when I got in or out of the car.

I took my car into the dealer when the noise first started and they told me they couldn't figure out what it was and and to drive "until it got worse"

So I drove for about 4 thousand miles with my car sounding like a piece, and took it back, and once again they told me that they couldn't figure it out.

After another 4k I was ready for my 65k service and took it in (on a Friday) and told them not to give it back to me with out figuring out what the noise was, which had gotten much louder by now than it had been originally. They at first tried to tell me that they couldn't figure it out and I took the technician out and I drove and made the car make the noise so he realized it was really bad (they had just been trying to make it make the noise in the garage).

They told me it would take a day to figure out so I brought my car back on the following monday. By 12:30 I got a call and they had figured out that the front sub frame weld had come undone. I had 2 options: 1, they could weld it back, which runs the risk of cracking again (which my money is on here in Michigan). Or 2 they could replace the front sub assembly for $1000ish (which really means prolly $1500).

I opted for the weld and was going to try and get Audi to pay for the full replacement after talking to Audi of North America. However, the decision to get it fixed for free (or at a discount) was the service managers decision, and he has decided that he thinks that it was an outside factor that has caused the damage. The thing is, I've never been in an accident, and all my service has been done at the dealer, I've never hit a huge pothole resulting in problems with the car or any outside factor that would result in such a problem.

I read some online about this and saw that other people have had similar problems with their Audi and this has been a bigger problem for BMWs.

Has anyone had this problem/gotten their dealer to fix it?

Thanks

 

Unless you were in an accident, there is no reason for welds to break at your relatively low mileage. The OEMs spend a lot of money on robot welders and inspectors, but bad welds still happen. I'd have a long discussion with AoA about fixing it under some kind of warranty, especially since you have reported it for quite a while. If they repair it, I'd take it to a "real" welding shop afterwards and have them check it out as well.

The potholes in MI are terrible, but anything deep enough to bust a weld are going to ruin the alignment, a tire, rim, and suspension at the same time.

 

Hi,

I, too, am having the identical problem with my A4 as you did with your Audi. I have been complaining since year 1. I have never been in any type of accident or major pothole. And now after 75,000 miles they 'chose' to look into it. (they looked into it for 2 months)

Unfortunately for me, they are saying it's my doings and there is 'no warranty' that would've covered it taking it back from day 1. Forget that i've been complaining for 4 yrs now (my car is an 2007 A4). Somehow I believe they are trying to gouge me for $$. Which sucks considering I've been loyal to them through 2 audis in 8 yrs.

They say i need to replace the front subframe for a hefty $1500.

My question to you is: did you find an alternative to yours? And if so, can you please share...as I am running in circles here trying to figure it out. Did Audi of America do anything to pick up the cost?

Kind Regards.